JP6061866B2 - Method for obtaining a lipid-containing composition from microbial biomass - Google Patents

Description

  This application is a provisional application 61 / 441,836 filed February 11, 2011, filed February 11, 2011, which is incorporated herein by reference in its entirety. Provisional Patent Application No. 61 / 441,842, United States Provisional Patent Application No. 61 / 441,849 filed on February 11, 2011, United States Provisional Patent Application filed on February 11, 2011 We claim the benefit of application 61 / 441,854 and US provisional application 61 / 487,019 filed May 17, 2011.

  The present invention relates to a method for obtaining a lipid-containing fraction from microbial biomass. In particular, a method is provided for pelleting microbial biomass, extracting the extracted oil from the pelleted biomass, and distilling the extracted oil at least once under short-path distillation conditions to obtain a lipid-containing fraction. This lipid-containing fraction can be further enriched.

  Microorganisms such as filamentous fungi, yeasts and algae produce a variety of lipids including fatty acyls, glycerolipids, phospholipids, sphingolipids, saccharolipids, polyketides, sterol lipids and prenol lipids. It is advantageous to extract some of these lipids from the microbial cells from which they are produced, and various methods have therefore been implemented.

  One class of lipids commonly extracted from microorganisms are glycerolipids, which contain fatty acid esters of glycerol (“triacylglycerol” or “TAG”). TAG is the primary storage unit for fatty acids and can therefore contain long chain polyunsaturated fatty acids (PUFA), as well as short chain saturated and unsaturated fatty acids and long chain saturated fatty acids. There is increasing interest in including PUFAs such as eicosapentaenoic acid [“EPA”; ω-3] and docosahexaenoic acid [“DHA”; ω-3] in pharmaceuticals and foods. Accordingly, a means for efficiently and cost-effectively extracting, refining and purifying lipid compositions containing PUFAs is particularly desirable.

  Many typical lipid isolation procedures involve disruption of microbial cells (eg, via mechanical, enzymatic or chemical means) followed by oil extraction using organic or low pollution solvents. The disruption process releases intracellular lipids from the microbial cells and makes them easily accessible by solvents during extraction. After extraction, the solvent is typically removed (eg, by evaporation, eg, by applying a vacuum, changing temperature or pressure, etc.).

  The resulting extracted oil is enriched with lipophilic constituents that accumulate in the fat body. In general, the major components of the fat body consist of TAG, ergosterol esters, other sterol esters, free ergosterol and phospholipids. The PUFA present in the fat body is mainly as a constituent of TAG, diacylglycerol, monoacylglycerol, phospholipids and free fatty acids. Subsequently, the extracted oil can be refined to produce a highly purified PUFA enriched TAG fraction. Final specifications for purified TAG fractions may be application dependent, such as oils as additives or supplements (eg in food compositions, specialty formulas, animal feeds, etc.), cosmetic or pharmaceutical compositions, etc. Depending on whether or not to use. Acceptable pollutant standards impose themselves (specific pollutants can cause undesirable properties such as haze / turbidity, odor) or external nutrition boards (eg A Voluntary Monograph Of The Council for Responsible Nutrition) [Washington, DC], March 2006 provides the maximum acid, peroxide, anisidine, TOTOX, polychlorinated dibenzo-para-dioxin and polychlorinated dibenzofuran values for ω-3EPA, ω-3DHA and mixtures thereof. Stipulate).

  Patent Document 1 discloses a microbial PUFA-containing oil having a high triglyceride content and high oxidative stability. Further, a method of recovering such oil from microbial biomass derived from pasteurized fermentation broth, wherein the microbial biomass is subjected to extraction to form granular particles, dried, and then using a suitable solvent A method for extracting oil from dry granules is described.

  Patent Document 2 is a method for extracting a fat-soluble component contained in a microbial cell, wherein the microbial cell containing the fat-soluble component is dried, and at the same time, the dried microbial cell is crushed and used by using an extruder. Disclosed is a method that requires forming the fat-soluble constituents formed into pellets and extracting them by use of an organic solvent.

  Patent Document 3 discloses a method of obtaining lipid from a composition containing cells and water, the method comprising contacting the composition with a desiccant and recovering the lipid from the cells.

Patent Document 4 discloses a method for concentrating a PUFA part in a fish oil containing a relatively low proportion of saturated and monounsaturated fatty acid parts having the same chain length as the PUFA part to be concentrated. Disclosed is a process comprising transesterifying to form a mixture of lower alkyl fatty acid esters and extracting the esters with carbon dioxide (CO ₂ ) under supercritical conditions.

Non-Patent Document 1 discloses a process flow diagram developed for a continuous countercurrent supercritical CO ₂ fractionation method that produces high concentration EPA. The raw material for this process is urea crystallized ethyl ester of herring oil, and the basis for the design is a product concentration of 90% EPA (ethyl ester) in 90% yield.

  There is a need for methods that can regulate the distribution of TAG, diacylglycerol, monoacylglycerol, and free fatty acids in PUFA-containing lipid compositions. A method for obtaining a PUFA-containing lipid composition having improved oxidative stability is desirable. A method of obtaining a PUFA-containing lipid composition enriched in TAG is also desirable. This is because it is an economical way to obtain such a composition.

  Patent Document 5 extracts a microbial oil containing PUFA (eg, from Mortierella alpina) with a polar solvent to extract at least one sterol (eg, desmosterol) that is soluble in the solvent. And then separating at least a portion of the sterol containing solvent from the oil, wherein the oil has a sterol content of less than 1.5%.

  Patent Document 6 is a method for recovering neutral fat containing PUFA from microbial biomass (for example, Schizochytrium), in which the biomass is contacted with a nonpolar solvent in the extraction process, and the lipid composition is recovered. Refining and / or bleaching and / or deodorizing the product, adding a polar solvent to the lipid composition, cooling the mixture to at least one other compound (eg, trisaturated glycerides, phosphorus-containing materials, wax esters, Saturated fatty acid-containing sterol esters, sterols, squalenes, hydrocarbons) are selectively precipitated and then removed from the lipid composition.

  Conventional methods avoid exposure to high temperatures of PUFAs, specifically polyunsaturated fatty acids, from microbial oils to ergosterol (ergosta-5,7,22-trien-3β-ol; CAS Registry Number 57-87. -4)) The short stroke distillation technique was not used as an effective means to remove contaminants.

  U.S. Patent No. 6,057,031 introduces PUFA production from a feed mixture comprising introducing the feed mixture into a simulated or actual moving bed chromatographic apparatus having a plurality of linked chromatography columns containing aqueous alcohol as an eluent. A chromatographic separation method for recovering a product, wherein the apparatus has a plurality of zones including at least a first zone and a second zone, each zone recovering a liquid from the plurality of coupled chromatography columns. A raffinate stream having an extract stream and a raffinate stream that can be (a) containing the PUFA product together with a more polar component from the column in the first zone, and in the second zone And / or (b) make the PUFA product less polar. The extract stream containing together with the other components is recovered from the columns in the second zone and introduced into non-adjacent columns in the first zone, and the PUFA product is fed into the feed mixture in each zone. A method of separating from different components is disclosed. Various fish oil-derived raw materials have been refined to produce more than 85-98% EPA ethyl ester. Patent document 8 demonstrated a method for recovering EPA and DHA from fish oils in high purity, but the disclosure describes a suitable feed mixture as "separate feed oil from microorganisms including genetically modified plants, animals and yeast. It also describes what can be obtained from the “combining source”. Furthermore, “genetically modified yeast is particularly suitable when the desired PUFA product is EPA”.

US Pat. No. 6,727,373 US Pat. No. 6,258,964 US Patent Application Publication No. 2009/0227678 U.S. Pat. No. 4,675,132 US Pat. No. 6,166,230 (GIST-Brocades) US Pat. No. 7,695,626 (Martek) International Publication No. 2011 / 080503A2 Pamphlet International Publication No. 2001 / 080503A2 Pamphlet

V. J. et al. Krukonis et al. , Adv. Seafood Biochem. , Pap. Am. Chem. Soc. Annu. Meet. (1992), Meeting Date 1987, 169-179.

In the first embodiment, the present invention provides:
(A) pelletizing microbial biomass having a certain moisture level and containing oil-bearing microorganisms;
(B) extracting the pelleted microbial biomass of step (a) to produce an extracted oil; and (c) distilling the extracted oil of step (b) at least once under short path distillation conditions. Wherein the distillation produces a distillate fraction and a lipid-containing fraction.

  In a second embodiment of the method, the oleaginous microorganism is selected from the group consisting of yeast, algae, fungi, bacteria, Euglena, stramenopile and oomycete. Preferably, the yeast is Yarrowia.

  In the third embodiment of the method, the oil-containing microorganism comprises at least one polyunsaturated fatty acid in the oil, and the polyunsaturated fatty acid is preferably linoleic acid, γ-linolenic acid, eicosadienoic acid, dihomo. -Γ-linolenic acid, arachidonic acid, docosatetraenoic acid, ω-6 docosapentaenoic acid, α-linolenic acid, stearidonic acid, eicosatrienoic acid, eicosatetraenoic acid, eicosapentaenoic acid, ω-3 docosapenta Selected from the group consisting of enoic acid and docosahexaenoic acid.

  In a fourth embodiment of the method, the moisture level of the microbial biomass ranges from about 1 to 10 weight percent microbial biomass.

In a fifth embodiment of the method, the step (a) of pelletizing microbial biomass comprises:
(1) mixing microbial biomass and at least one oil-absorbable grinding agent to provide a crushed biomass mixture comprising crushed microbial biomass;
(2) blending the crushed biomass mixture with at least one binder to provide a fixable mixture capable of forming solid pellets; and (3) forming the fixable mixture into solid pellets and pellets Providing modified microbial biomass.

Preferably, the step (1) of mixing the microbial biomass and the step (2) of blending at least one binder are carried out in an extruder, carried out at the same time, or carried out simultaneously in an extruder; The step (3) of forming the solid pellets from a simple mixture comprises:
(I) extruding the fixable mixture through a die to form a strand;
A combination of (ii) drying and breaking the strand; and (iii) extruding the fixable mixture through a die to form a strand and drying and breaking the strand (ii) A step selected from the group consisting of:

  In a sixth embodiment of the method, the crushed microbial biomass is: (a) a total specific energy input of about 0.04 to 0.4 KW / (kg / hr); (b) a bush having a progressively shorter pitch length. Produced by crushing in a twin screw extruder including a compression zone using elements; and (c) a compression zone using flow restriction; in the extruder, the compression zone precedes the compression zone.

In a seventh embodiment of the method, the at least one grinding agent is preferably
(A) the at least one grinding agent is a particle having a Moh hardness of 2.0 to 6.0 and an oil absorption coefficient of 0.8 or greater measured according to ASTM method D1483-60;
(B) the at least one grinding agent is selected from the group consisting of silica and silicate; and (c) the at least one grinding agent is the weight of microbial biomass, grinding agent and binder in the solid pellet. Present from about 1 to 20 percent by weight relative to the sum of
Having a characteristic selected from the group consisting of

The at least one binder is preferably
(A) the at least one binder is selected from water and carbohydrates selected from the group consisting of sucrose, lactose, fructose, glucose, and soluble starch; and (b) the at least one binder is solid Present from about 0.5 to 10 percent by weight relative to the sum of the weight of microbial biomass, grinding agent and binder in the pellet;
Having a characteristic selected from the group consisting of

In an eighth embodiment of the method, the pellet is
(A) the pellets have an average diameter of about 0.5 to about 1.5 mm and an average length of about 2.0 to about 8.0 mm; and (b) the pellets are microbial biomass in solid pellets About 1 to about 20 weight percent of at least one oil-absorbable grinding agent, and about 0. 0 to about 20 weight percent of the microbial biomass, including about 70 to about 98.5 weight percent of the oil-bearing microorganisms. Having a property selected from the group consisting of 5 to 10 weight percent comprising at least one binder.

  In a ninth embodiment of the method, the extraction is performed with an organic solvent to produce an extracted oil, and the extracted oil is degummed prior to step (c) of distilling the extracted oil, optionally. to bleach.

In a tenth embodiment of the method, the extraction is:
(1) Treating pelletized microbial biomass with a solvent containing liquid or supercritical fluid carbon dioxide (the pelleted microbial biomass containing oil-containing microorganisms is
(I) an extract comprising a lipid fraction substantially free of phospholipids; and (ii) residual biomass comprising phospholipids;
To further obtain at least one polyunsaturated fatty acid in the oil) :) and (2) at least one polyunsaturated by fractionating the extract obtained in step (1) section (i) at least once Obtaining an extracted oil having a refined lipid composition comprising fatty acids (the refined lipid composition is enriched with triacylglycerol relative to the oil composition of pelleted microbial biomass not treated with solvent)
including.

  In an eleventh embodiment of the method, the extracted oil of step (b) contains a sterol fraction, the distillate fraction of step (c) contains a sterol, and the lipid-containing fraction of step (c) is A reduced amount of sterol compared to the amount of sterol in the extracted oil that has not been subjected to short path distillation. The sterol fraction may comprise one or more sterols selected from the group consisting of stigmasterol, ergosterol, brassicasterol, campesterol, β-sitosterol and desmosterol.

  In a twelfth embodiment of the method, a refined lipid composition enriched with triacylglycerols against an oil composition of pelleted microbial biomass comprising at least one polyunsaturated fatty acid and not treated with a solvent The extracted oil with the product further comprises at least 300 mg / 100 g of sterol fraction. During at least one distillation under short-path distillation conditions, a distillate fraction containing sterols was produced, of triacylglycerol and sterols in the extracted oil having refined lipid composition that was not subjected to short-path distillation. A lipid-containing fraction containing a reduced amount of sterol compared to the amount is produced.

In a thirteenth embodiment, the method includes:
(D) further transesterifying the lipid-containing fraction of step (c); and (e) enriching the transesterified lipid-containing fraction of step (d) to obtain an oil concentrate.

  In a fourteenth embodiment, oleaginous microorganisms accumulate as microbial oil in excess of 25% of their dry cell weight; microbial oil is measured as 30 to 70 weight percent eicosapentaene, measured as weight percent of total fatty acids. Containing acid, substantially free of docosahexaenoic acid, enrichment of step (e) is by a combination of at least two processes, said first process comprising fractional distillation, said second process Is selected from the group consisting of urea adduct formation, liquid chromatography, supercritical fluid chromatography, simulated moving bed chromatography, actual moving bed chromatography and combinations thereof; the oil concentrate is measured as a weight percent of oil. At least 70 weight percent eicosapentaenoic acid, and substantially comprising docosahexaene The eicosapentaenoic acid free concentrate.

Biological Deposits The following biological materials have been deposited with the American Type Culture Collection (ATCC), 10801 University Boulevard, Manassas, VA 20110-2209, and have the following names, deposit numbers and deposit dates.

  The biological materials listed above were deposited in accordance with the provisions of the Budapest Treaty concerning the international recognition of deposits of microorganisms in patent proceedings. The listed deposited strains will be maintained at a designated international depository agency for at least 30 years and will be publicly available upon grant of a patent disclosing it. The availability of the deposited stock is not considered an authorization to carry out the subject invention by losing the patent rights granted by the government.

  Yarrowia lipolytica Y4305 was derived from Y. lipolytica Y4128 according to the methodology described in US Patent Application Publication No. 2009-0093543-A1. Y. lipolytica Y9502 was derived from Yarrowia lipolytica Y8412 according to the methodology described in US Patent Application Publication No. 2010-0317072-A1. Similarly, Yarrowia lipolytica Y8672 was derived from Y. lipolytica Y8259 according to the methodology described in US Patent Application Publication No. 2010-0317072-A1.

A custom-made high-pressure extraction device flow sheet will be described. 1 schematically illustrates one embodiment of an extraction in which pelleted microbial biomass is contacted with CO ₂ to obtain an extract that is then fractionated. 1 schematically illustrates one embodiment of extraction in which microbial biomass is contacted with CO ₂ to obtain an extract. It is a graph display of the extraction curve obtained in Example 12. An overview of the method of the present invention is provided in the form of a flowchart. Specifically, microbial fermentation produces untreated microbial biomass which is then pelletized. Oil extraction of solid pellets results in residual biomass and extracted oil. Distillation of the extracted oil using short path distillation (SPD) conditions produces a distillate fraction and a lipid-containing fraction, which can optionally be further transesterified and enriched to yield an oil concentrate. The following are provided: plasmid map of pZKUM; and (B) pZKL3-9DP9N.

  The following sequence is 37C. F. R. §1.821-1.825 ("Requirements for Patent Applications Containing Nucleotide Sequences and / or Amino Acid Sequence Disclosures-Sequence Rules Containing Nucleotide Sequences and / or Amino Acid Sequences-Rules) , World Intellectual Property Organization (WIPO) standard ST. 25 (1998) and the EPO and PCT sequence listing requirements (Rules 5.2 and 49.5 (a-2), as well as Detailed Bylaws 208 and Annex C). The symbols and format used for nucleotide and amino acid sequence data are 37C. F. R. Follow the rules set forth in §1.822.

  SEQ ID NOs: 1-8 are open reading frames, proteins (or portions thereof), or plasmids that encode genes, as specified in Table 1.

  The disclosures of all patent and non-patent literature cited herein are hereby incorporated by reference in their entirety.

  Where an amount, concentration, or other value or parameter is listed as a range, preferred range, or list of preferred upper and preferred lower values, this may be any range, regardless of whether the range is disclosed individually. It should be understood that all ranges formed from any pair of an upper limit or preferred upper value and any lower range limit or preferred lower value are specifically disclosed. Where numerical ranges are cited herein, unless otherwise stated, the ranges are intended to include the end points thereof and all integers and fractions within the ranges. It is not intended that the scope of the invention be limited to the specified values in defining the range.

  As used herein, the terms “comprises”, “comprising”, “includes”, “including”, “has”, “having”, “Contains” or “containing”, or any other variation thereof, is intended to cover non-exclusive inclusions. For example, a composition, mixture, process, method, article, or device that includes an enumeration of elements is not necessarily limited to only those elements, but is not expressly listed or such a composition, It may include mixtures, processes, methods, articles, or other elements specific to the device. Further, unless expressly stated to the contrary, “or” refers to inclusive or not exclusive or. For example, condition A or B is satisfied by any one of the following: A is true (or present), B is false (or does not exist), and A is false (or does not exist) 1), B is true (or present), and A and B are true (or present).

  Also, the indefinite articles “a” and “an” preceding an element or component of the invention are intended to be non-limiting with respect to the number of instances (ie, incidence) of the element or component. Thus, “a” or “an” should be read to include one or at least one and the singular word form of an element or component is the plural unless the number clearly means the singular. Including.

  The term “invention” or “invention” as used herein is intended to refer to all aspects and embodiments of the invention described in the claims and herein, and any particular embodiment Or should not be read as limited to embodiments.

The following definitions are used in this disclosure:
“Carbon dioxide” is abbreviated as “CO ₂ ”.
“American Type Culture Collection” is abbreviated as “ATCC”.
“Polyunsaturated fatty acid” is abbreviated as “PUFA”.
“Phospholipid” is abbreviated “PL”.
“Triacylglycerol” is abbreviated as “TAG”.
“Free fatty acid” is abbreviated as “FFA”.
“Total fatty acid” is abbreviated as “TFA”.
“Fatty acid methyl ester” is abbreviated as “FAME”.
“Ethyl ester” is abbreviated as “EE”.
“Dry cell weight” is abbreviated as “DCW”.
“Millitorr” is abbreviated as “mTorr”.
“Short stroke distillation” is abbreviated as “SPD”.

  As used herein, the term “microbial biomass” refers to microbial cell material from microbial fermentation of oleaginous microorganisms carried out to produce microbial oil. The microbial biomass can be in the form of whole cells, whole cell lysates, homogenized cells, partially hydrolyzed cell material, and / or disrupted cells. Preferably, the microbial oil comprises at least one PUFA.

  The term “untreated microbial biomass” refers to microbial biomass prior to extraction with a solvent. Optionally, the untreated microbial biomass can be subjected to at least one mechanical process (eg, by drying the biomass, crushing the biomass, pelleting the biomass, or a combination thereof) prior to extraction with the solvent. The terms “untreated microbial biomass and unrefined microbial biomass” are used interchangeably herein.

  The term “pelletizing” or “pelletizing” refers to the process of producing solid pellets.

  The term “solid pellet” refers to a pellet that has structural rigidity and resistance to changes in shape or volume. The solid pellet is desirably non-sticky at room temperature. Most of the solid pellets can be filled together for days without decomposing the pellet structure, without bonding together; therefore, the majority is desirably a free-flowing pelletized composition . Solid pellets are formed herein from microbial biomass via a process of “pelleting” and can therefore also be referred to as “pelleted microbial biomass”.

  The term “crushed biomass mixture” refers to the product obtained by mixing microbial biomass and at least one grinding agent. The crushed biomass mixture includes crushed microbial biomass.

  The term “fractured microbial biomass” refers to microbial biomass that has been subjected to a crushing process, said crushing resulting in a crushing efficiency of at least 50% of the microbial biomass.

The term “crushing efficiency” is qualitatively measured by optical visualization or divided by the following formula:% crushing efficiency = (% free oil ^* 100) divided by (% total oil) (% free oil and% total oil) Refers to the percentage of the cell wall that is broken or ruptured during processing, measured quantitatively according to (measured for solid pellets). Increasing the disruption efficiency of microbial biomass typically results in an increased extraction yield of microbial oil contained within the microbial biomass.

  The term “percent total oil” refers to all oils present in solid pellet samples (eg, neutral fat fractions present in cell membranes, fat bodies, etc. [DAG, MAG, TAG], free fatty acids, phospholipids, etc. (Including fatty acids). Percent total oil is efficiently measured by converting all the fatty acids in the pelleted sample that has been subjected to mechanical crushing, followed by acyllipid methanolysis and methylation. Thus, the sum of fatty acids (expressed in triglyceride form) is interpreted as the total oil content of the sample. In the present invention, percent total oil is selectively measured by gently grinding solid pellets to a fine powder using a mortar and pestle and then weighing an aliquot (in triplicate) for analysis. Fatty acids in the sample (predominantly present as triglycerides) are converted to the corresponding methyl esters by reaction with acetyl chloride / methanol at 80 ° C. A C15: 0 internal standard is then added to each sample in known amounts for calibration purposes. Individual fatty acids are measured by capillary gas chromatography using flame ionization detection (GC / FID). Furthermore, the sum of fatty acids (expressed in triglyceride form) is taken as the total oil content of the sample.

  The term “percent free oil” refers to the amount of free and unbound oil (eg, fatty acids expressed in triglyceride form, but partially phospholipids) readily available for extraction from a particular solid pellet sample. Thus, for example, analysis of percent free oil does not include oil present in uncrushed membrane bound fat bodies. In the present invention, percent free oil is selectively measured by stirring the sample with n-heptane, centrifuging, and then evaporating the supernatant to dryness. The resulting residual oil is then weighed and expressed as a weight percentage of the original sample.

  The term “grinding agent” refers to an oil-absorbable agent that is mixed with microbial biomass to obtain a crushed biomass mixture. Preferably, the at least one grinding agent is present from about 1 to 50 parts per 100 parts microbial biomass. In some preferred embodiments, the grinding agent is silica or silicate. Other preferred properties of the grinding agent are discussed below.

  The term “fixable mixture” refers to a product obtained by blending at least one binder with a crushed biomass mixture. A fixable mixture is a mixture that can form solid pellets upon removal of the solvent (eg, removal of water in the drying process).

  The term “binder” refers to an agent that is blended with a crushed biomass mixture to obtain a fixable mixture. Preferably, the at least one binder is present from about 0.5 to 20 parts per 100 parts microbial biomass. In some preferred embodiments, the binding agent is a carbohydrate. Other preferred properties of the binder are discussed below.

  The term “residual biomass” as used herein refers to microbial cell material from microbial fermentation carried out to produce microbial oil that has been extracted at least once with a solvent (eg, an inorganic or organic solvent). . If the initial microbial biomass subjected to extraction is in the form of a solid pellet, the residual biomass can be referred to as “residual pellet”.

  The terms “reduced” or “depleted” have a smaller amount, eg, only slightly less than the original amount, or for example an amount that is completely missing in the defined material, and all intermediate Means to include the quantity.

  The term “lipid” refers to any fat-soluble (ie, lipophilic) natural molecule. Lipids are a diverse group of compounds with many important biological functions, such as structural components of cell membranes, energy conservation sources, and signaling pathway intermediates. Lipids can be broadly defined as hydrophobic or amphiphilic small molecules that are derived entirely or partially from either ketoacyl or isoprene groups. A general summary of lipids based on the Lipid Metabolites and Pathways Strategies (LIPID MAPS) classification system (National Institute of General Medical Sciences, Bethesda, MD) is shown in Table 2 below.

  The term “oil” refers to a lipid substance that is liquid at 25 ° C. and is usually polyunsaturated. In oleaginous organisms, oil constitutes the majority of total lipids. “Oil” is primarily composed of triacylglycerol (TAG), but may also contain other neutral fats, phospholipids (PL) and free fatty acids (FFA). The fatty acid composition in the oil and the fatty acid composition of the total lipid are generally similar; therefore, an increase or decrease in PUFA concentration in the total lipid corresponds to an increase or decrease in PUFA concentration in the oil, and vice versa. It is.

  “Microbial oil” is oil produced by microorganisms. This general term may refer to unconcentrated microbial oil, extracted oil, lipid-containing fraction, refined oil or concentrated microbial oil as further defined below. After purification or enrichment of defined fatty acids in microbial oils, the oils can exist in various chemical forms (eg, in the form of triacylglycerols, alkyl esters, salts or free fatty acids).

The term “extracted oil” refers to oil that has been separated from the cellular material from which the oil is synthesized, such as microorganisms. The amount of oil that can be extracted from microorganisms is often proportional to the crushing efficiency. Extracted oils are obtained through a wide range of methods, the simplest involving only physical means. For example, mechanical crushing using various press structures (eg, screws, expellers, pistons, bead beaters, etc.) can separate the oil from the cellular material. Alternatively, oil extraction is via treatment with various organic solvents (eg hexane, isohexane), enzymatic extraction, osmotic shock, ultrasonic extraction, supercritical fluid extraction (eg CO ₂ extraction), saponification and combinations of these methods. Can be done. The amount of oil that can be extracted from microorganisms is often proportional to the crushing efficiency. Furthermore, purification or concentration of the extracted oil is optional.

  The term “unconcentrated microbial oil” means that the extracted oil is not substantially enriched for one or more fatty acids. Thus, the fatty acid composition of the “unconcentrated microbial oil” is substantially similar to the fatty acid composition of the microbial oil produced by the microorganism. The unconcentrated microbial oil can be a non-concentrated extract oil or a non-concentrated refined oil.

The term “extracted oil with refined lipid composition” or “refined lipid composition” is the term used for supercritical carbon dioxide (CO ₂ ) extraction disclosed in US 2011 / 0263709-A1. It refers to the product microbial oil composition. Thus, the refined lipid composition is an extracted oil. The refined lipid composition may comprise neutral fat and / or FFA while being substantially free of PL. Refined lipid composition, American Oil Chemists'Society (AOCS) Official Method Ca 20-99, entitled "Analysis for Phosphorus in Oil by Inductively Coupled Plasma Optical Emission Spectroscopy " (Official Methods and Recommended Practices of the AOCS, 6 th ed , Urbana, IL, AOCS, 2009, incorporated herein by reference), preferably having less than 30 ppm phosphorus, more preferably less than 20 ppm phosphorus. The refined lipid composition may be enriched in TAG relative to the microbial biomass oil composition and may optionally include a sterol fraction. Refined lipid compositions can be subjected to further purification, for example via short path distillation as described herein, to produce “refined oils” or “lipid-containing fractions”.

  The term “degumming” refers to a process that reduces the concentration of phospholipids and other impurities from the extracted oil.

  The term “bleaching” refers to the process of reducing the concentration of pigment / colored compounds and residual metals from the extracted oil.

  The term “sterol” or “sterol fraction” refers to a biological component that affects membrane permeability within a cell. Although sterols have been isolated from all major groups of organisms, there exists a diversity of isolated sterols. The predominant sterol in higher animals is cholesterol, while β-sitosterol is generally the predominant sterol in higher plants (but is often accompanied by campesterol and stigmasterol). Generalization of the dominant sterols found in microorganisms is more difficult. This is because the composition depends on the specific microbial species. For example, the oleaginous yeast Yarrowia lipolytica contains mainly ergosterol, the fungi of the genus Mortierella mainly contain cholesterol and desmosterol, and the stramenopile of the genus Schizochytrium. Mainly includes brush castrol and stigmasterol. A summary of the sterols often found in sterol-containing microbial oils is shown in Table 3 below; in contrast, those sterols are typically not found in fish oil. The sterols in Table 3, when present in sterol-containing microbial oils, tend to precipitate from the extracted oil due to reduced solubility at high melting points and lower storage temperatures, resulting in turbid oils. It is highly desirable to minimize the undesired turbidity of the extracted oil or the oil produced therefrom by reducing the concentration of these sterols.

  The term “distill” refers to a method of separating mixtures based on their volatility differences in a boiling liquid mixture. Distillation is a unit operation, or physical separation process, not a chemical reaction.

  The term “Short Stroke Distillation” (“SPD”) means that the SPD device is operated in an extremely high vacuum, and the vaporizer from the material to be distilled after evaporation moves to the condensation surface only a short distance to the evaporator. Refers to a separation method with an internal condenser in close proximity to. As a result, the thermal decomposition from this separation method is minimal.

  The term “refined oil” refers to impurities at a reduced concentration compared to the concentration of impurities in the extracted oil, such as phospholipids, trace metals, free fatty acids, colored compounds, small amounts of oxidation products, volatiles and / or odors. It refers to an extracted oil having a compound as well as a sterol (eg, ergosterol, brassicasterol, stigmasterol, cholesterol). The refining process typically does not concentrate or enrich the microbial oil so that certain fatty acids are substantially enriched, and therefore the refined oil is most often unconcentrated.

  The terms “lipid-containing fraction” and “SPD refined oil” are used interchangeably herein. These terms refer to an extracted microbial oil containing a TAG fraction containing one or more PUFAs that has been subjected to at least one distillation process under SPD conditions. When a sterol fraction is present in the extracted oil, the distillation process reduces the amount of sterol in the lipid-containing fraction as compared to the sterol content of the oil prior to short path distillation.

  SPD can concentrate ethyl esters, methyl esters and free fatty acids, but the process typically does not concentrate TAG (eg, unless run at extremely high temperatures and then result in TAG degradation). . Since most PUFAs in the lipid-containing fraction are in the form of TAG, the SPD process typically does not concentrate the TAG so that certain fatty acids are substantially enriched, and the lipid-containing fraction Is most often considered unconcentrated for the purposes described herein.

  The term “esterification” refers to an acid or base catalyzed chemical reaction that converts an ester of a fatty acid to an ester of a different fatty acid.

  “Fatty acid ethyl ester” [“FAEE”] generally refers to the chemical form of a lipid derived synthetically by reacting free fatty acids or their derivatives with ethanol in the process of esterification or transesterification.

  The term “enrichment” refers to the process of increasing the concentration of one or more fatty acids in a microbial oil relative to the concentration of one or more fatty acids in an unconcentrated microbial oil. For example, as discussed herein, a microbial oil containing 30 to 70 wt% of the desired PUFA, measured as wt% of TFA, is enriched or concentrated to produce an "oil concentrate".

  The term “oil concentrate” refers to an oil containing at least 70% by weight of the desired PUFA, measured as a weight% of the oil. Preferably, the oil concentrate is obtained from a microbial oil containing from 30 to 70% by weight of the desired PUFA, measured as weight percent of total fatty acids, said microbial oil as dry oil weight of oil as detailed below. Obtained from oil-bearing microorganisms that accumulate in excess of 25%. Specifically, ethyl or other esters of microbial oil can be enriched with the desired PUFA and can be separated by methods commonly used in the art.

  The term “eicosapentaenoic acid concentrate” or “EPA concentrate” is an oil concentrate comprising at least 70% by weight of EPA, measured as weight percent of oil, and substantially free of DHA. Refers to oil. The EPA concentrate is obtained from a microbial oil that contains 30 to 70% by weight of EPA, measured as weight percent of total fatty acids, and is substantially free of DHA, said microbial oil having 25% of the dry cell weight as oil. Obtained from excess oil-bearing microorganisms. At least 70% by weight of the EPA is in the form of free fatty acids, triglycerides (eg, TAG), esters, and combinations thereof. The ester is most preferably in the form of an ethyl ester.

  “Neutral fat” refers to lipids that are commonly found in fat body cells as storage fat, and are so named because lipids do not carry charged groups at the pH of the cell. In general, they are completely non-polar and have no affinity for water. Neutral fat generally refers to mono-, di-, and / or triesters of glycerol with fatty acids, also referred to as monoacylglycerol (MAG), diacylglycerol (DAG) or triacylglycerol (TAG), respectively, or Collectively also referred to as acylglycerol. In order to release FFA from acylglycerol, a hydrolysis reaction must occur.

  The term “triacylglycerol” is synonymous with the term “triacylglyceride” and refers to a neutral fat composed of three fatty acyl residues esterified to a glycerol molecule. The TAG can contain long chain PUFAs and saturated fatty acids, as well as short chain saturated and unsaturated fatty acids. In living organisms, TAG is the primary storage unit for fatty acids. This is because the glycerol backbone helps stabilize the PUFA molecule for storage or during transport. In contrast, free fatty acids are rapidly oxidized.

  As used herein, the term “total fatty acid (TFA)” is derivatized into fatty acid methyl ester (FAME) by a base transesterification method (known in the art) in a given sample, which can be, for example, microbial biomass or oil. Refers to the sum of all cellular fatty acids that can be converted. Thus, total fatty acids include fatty acids from the neutral fat fraction (including DAG, MAG, and TAG) and from the polar lipid fraction (including the phosphatidylcholine and phosphatidylethanolamine fractions), but not FFA.

  The term “total lipid content” of a cell is a measure of TFA as a percentage of dry cell weight (DCW), but total lipid content is approximated as a measure of FAME as a percentage of DCW (FAME% DCW). Can be made. Thus, the total lipid content (TFA% DCW) is equal to, for example, milligrams of total fatty acids per 100 milligrams of DCW.

  The concentration of fatty acids in the total lipid is expressed herein as weight percent of TFA (% TFA), eg, milligrams of a given fatty acid per 100 milligrams of TFA. Unless otherwise specifically stated in this disclosure, a reference to the percentage of a given fatty acid relative to total lipids in microbial cells and microbial oils is equivalent to the concentration of fatty acids as% TFA (eg, total lipids % EPA is equivalent to EPA% TFA).

  The concentration of fatty acid ester (and / or fatty acid and / or triglyceride, respectively) in the oil concentrate is the weight percent ["% oil"] of the oil, eg, a given fatty acid ester (and per 100 milligrams of oil concentrate (and (Or fatty acids and / or triglycerides, respectively). This unit of measure is used to describe, for example, the concentration of EPA in the EPA concentrate.

In some cases, it is useful to express a given fatty acid content in a cell as a weight percent (% DCW) of its dry cell weight. Thus, for example, eicosapentaenoic acid% DCW is determined according to the following formula: (eicosapentaenoic acid% TFA) ^* (TFA% DCW)] / 100. However, a given fatty acid content in cells as a weight percent (% DCW) of dry cell weight can be approximated as follows:
(Eicosapentaenoic acid% TFA) ^* (FAME% DCW)] / 100.

  The terms “lipid profile” and “lipid composition” are synonymous and refer to the amount of individual fatty acids contained in a particular lipid fraction, such as in total lipids or oils, the amount as a weight percent of TFA. Expressed. The sum of the individual fatty acids present in the mixture should be 100.

The term “fatty acid” refers to varying long chain fatty acids (alkanoic acids) of about C ₁₂ to C ₂₂ chain length, but both longer and shorter chain acids are also known. The predominant chain lengths _are between _{C 16} of _{C 22.} The structure of the fatty acid is represented by a simplified notation system of “X: Y” (where X is the total number of carbon [“C”] atoms in the specific fatty acid and Y is the number of double bonds). . “Saturated fatty acids” and “unsaturated fatty acids”, “monounsaturated fatty acids” and “polyunsaturated fatty acids” (PUFA), and “ω-6 fatty acids” (“ω-6” or “n-6”) Additional details regarding the distinction between “ω-3 fatty acids” and “ω-3” or “n-3” are provided in US Pat. No. 7,238,482, incorporated herein by reference. ing.

  The nomenclature used to describe PUFA herein is shown in Table 4. In the column entitled “abbreviation”, the ω-reference system is used to determine the number of carbons, the number of double bonds, and the position of the double bond closest to the ω carbon counted from the first ω carbon for this purpose. Show. The rest of the table summarizes the common names of omega-3 and omega-6 fatty acids and their precursors, abbreviations used throughout the specification, and the chemical names of the respective compounds.

  As used in this disclosure, the terms EPA, DHA, NDPA and HPA each refer to their respective acids or acid derivatives (eg, glycerides, esters, phospholipids, amides, lactones, salts, unless specifically stated otherwise) Etc.). For example, “EPA-EE” specifically refers to EPA ethyl ester.

  NDPA and HPA are commonly found in fish oil. Concentrated EPA produced from fish oil often contains those fatty acids as impurities in the final EPA composition (see, for example, US 2010-0278879 and WO 2010/147994 A1). ).

  The term “substantially free of DHA” is meant to include about 0.05 weight percent or less of DHA. Thus, an EPA concentrate is substantially when the concentration of DHA (in the form of free fatty acids, triacylglycerols, esters and combinations thereof) is less than about 0.05% by weight of DHA, measured as the weight percent of oil. DHA is not included. Similarly, microbial oils are substantially DHA (free fatty acids, triacylglycerols, esters, and their) when the concentration of DHA is less than about 0.05% by weight of DHA, measured as the weight percent of TFA. Does not include combination form.

  The terms “substantially free of NDPA” and “substantially free of HPA” are equivalent to the definitions provided above for the term “substantially free of DHA”, but with the fatty acid NDPA or HPA is used instead of DHA, respectively.

  The term “high level PUFA production” refers to a PUFA of at least about 25% of the total lipid of the microbial host, preferably a PUFA of at least about 30% of the total lipid, more preferably a PUFA of at least about 35% of the total lipid. More preferably, at least about 40% PUFA of total lipid, more preferably at least about 40-45% PUFA of total lipid, more preferably at least about 45-50% PUFA of total lipid, more preferably It refers to the production of at least about 50-60% PUFA, most preferably at least about 60-70% PUFA of total lipids. The structural form of PUFA is not limited; thus, for example, PUFA can be present in the total lipid as FFA or in an esterified form, such as acylglycerol, phospholipid, sulfur lipid or glycolipid.

  The term “oil-containing microorganism” refers to a microorganism capable of producing microbial oil. Thus, the oleaginous microorganism can be a yeast, algae, Euglena, stramenopile, fungi, or a combination thereof. In a preferred embodiment, the oleaginous microorganism is oleaginous.

The term "oleaginous" refers to those energy sources refers to those organisms that tend to store in the form of an oil ^{(Weete, In:. Fungal Lipid} Biochemistry, 2 nd Ed, Plenum, 1980). In general, oleaginous cell oils follow a sigmoidal curve, where lipid concentration increases until it reaches a maximum in late logarithmic or early stationary phase, and then gradually decreases during late stationary phase and death (Yongmantkai and Ward) , Appl. Environ. Microbiol., 57: 419-25 (1991)). It is not uncommon for oleaginous microorganisms to accumulate as oil in excess of about 25% of their dry cell weight.

  Examples of oleaginous organisms include, but are not limited to, Mortierella, Thraustochytrium, Schizochytrium, Yarrowia, Candida, Rhodola, Rhodolo Included are organisms of the genus selected from the group consisting of (Rhodosporium), Cryptococcus, Trichosporon, and Lipomyces.

  The term “oleaginous yeast” refers to oleaginous microorganisms classified as yeasts capable of producing oil. Examples of oleaginous yeast include, but are in no way limited to the following genera: Yarrowia, Candida, Rhodotorula, Rhodosporidium, Cryptococcus, Trichosporon (Trichosporon) ) And Lipomyces.

  As used herein, the term “medicine” refers to a compound or substance controlled by Section 503 or 505 of the Federal Food, Drug and Cosmetic Act, when sold in the United States. Means.

  The term “substantially free of environmental pollutants” means that the oil concentrate or EPA concentrate respectively contains no environmental pollutants or at most only trace amounts of environmental pollutants. Are compounds such as polychlorinated biphenyls [“PCB”] (CAS number 1336-36-3), dioxins, brominated flame retardants and insecticides (eg, toxaphene and dichlorodiphenyltrichloroethane [“DDT”] and its metabolites) Is included.

  In general, lipid accumulation in oleaginous microorganisms is induced in response to the total carbon to nitrogen ratio present in the growth medium. This process leading to de novo synthesis of free palmitate (16: 0) in oleaginous microorganisms is described in detail in US Pat. No. 7,238,482. Palmitate is a precursor of longer chain saturated and unsaturated fatty acid derivatives formed through the action of elongases and desaturases.

A wide range of fatty acids (including saturated and unsaturated fatty acids and short and long chain fatty acids) can be incorporated into TAG, the primary storage unit for fatty acids. In the oleophilic microorganisms described herein, incorporation of long chain PUFAs into TAG is most desirable, but the structural form of PUFA is not limited (eg, EPA as FFA in total lipids or esterified form) For example, acyl glycerol, phospholipids, sulpholipids or glycolipids). More specifically, in one embodiment, the oleaginous microorganism is LA, GLA, EDA, DGLA, ARA, DTA, DPAn-6, ALA, STA, ETrA, ETA, EPA, DPAn-3, DHA and mixtures thereof. Generating at least one PUFA selected from the group consisting of: More preferably, at least one PUFA is at least _{C 20} chain length, for example, EDA, DGLA, ARA, DTA , DPAn-6, ETrA, ETA, EPA, from DPAn-3, DHA, and mixtures thereof Have the PUFA selected.

  In one embodiment, the at least one PUFA is selected from the group consisting of ARA, EPA, DPAn-6, DPAn-3, DHA and mixtures thereof. In another preferred embodiment, the at least one PUFA is selected from the group consisting of EPA and DHA.

  Most PUFAs are incorporated into TAG as neutral fat and stored in the fat body. However, it is important to note that the total PUFA measurement in oily organisms should minimally include phosphatidylcholine, phosphatidylethanolamine and PUFAs localized in the TAG fraction.

The present invention
(A) pelletizing microbial biomass having a certain moisture level and containing oil-bearing microorganisms;
(B) extracting the pelleted microbial biomass of step (a) to produce an extracted oil; and (c) distilling the extracted oil of step (b) at least once under short path distillation conditions. Wherein the distillation produces a distillate fraction and a lipid-containing fraction.

In another embodiment, the method comprises the following steps:
(D) transesterifying the lipid-containing fraction of step (c); and (e) enriching the transesterified lipid-containing fraction of step (d) to obtain an oil concentrate.

  Although the present invention relates to a method for obtaining a lipid-containing fraction or oil concentrate from pelleted microbial biomass, a related method that may be useful for obtaining the oil-containing microorganism itself is also described in the schematic diagram of FIG. Each of the aspects of FIG. 5 will be discussed in more detail below, with bold in the figure referring to the defining portion of FIG.

  Oil-bearing microorganisms produce microbial biomass as they grow and propagate, typically through microbial fermentation. Microbial biomass can be from any microorganism that can produce microbial oil, whether natural or recombinant (“gene engineering”). Thus, for example, the oil-bearing microorganism can be selected from the group consisting of yeast, algae, Euglena, stramenopile, fungi, and mixtures thereof. Preferably, the microorganism is capable of high level PUFA production in microbial oil.

  By way of example, commercial sources of ARA oils are typically from microorganisms of the genus Mortierella (filamentous fungi), the genus Entomophthora, the genus Pythium and the genus Porphyridium (red algae). Generated. Most notably, Martek Biosciences Corporation (Columbia, MD) produces an ARA-containing fungal oil (ARASCO®; US Pat. No. 5,658,767), which substantially produces EPA. It is not included and is derived from either Mortierella alpina or Pythium insidiosum.

  Similarly, EPA can be produced utilizing microorganisms through a number of different methods based on the natural capacity of the defined microorganism being utilized [eg, heterotrophic diatom Cycloterra species and Nitzschia. ) Species (US Pat. No. 5,244,921); Pseudomonas sp., Alteromonas sp. Or Shewanella sp. (US Pat. No. 5,246,841); Pythium ) Fungi (US Pat. No. 5,246,842); or Mortierella elongata, M. et al. M. exigua, or M. Hygrophila (US Pat. No. 5,401,646); and Nannochloropsis spp. Krienitz, L. and M. Wirt, Limnologica, 36: 204-210 (2006))].

  DHA can also be produced using methods based on the natural ability of natural microorganisms. For example, Schizochytrium species (US Pat. No. 5,340,742; US Pat. No. 6,582,941); Ulkenia (US Pat. No. 6,509,178); Pseudomonas sp. YS-180 (US Pat. No. 6,207,441); Thraustochytrium genus LFF1 (US Patent Publication No. 2004/0161831 A1); Crypthecodinium (U.S. Patent Application Publication No. 2004 / 0072330A1; deSwaaf, ME et al. Biotechnol Bioeng., 81 (6): 666-672 (200) 3) and Appl Microbiol Biotechnol., 61 (1): 40-43 (2003)); Emiliaia species (Japanese Patent Application Laid-Open No. 5-308978 (1993)); and Japonochytrium species (ATCC #) 28207; JP-A-199588 / 1989], and the following microorganisms are known to have the ability to produce DHA: Vibrio marinus (bacteria isolated from the deep sea; ATCC # 15381); microalgae Cycloterra cryptica and Isochrysis galvana; and flagellates such as Thraustokitori Thraustochytrium species referred to as Thraustochytrium aureum (ATCC # 34304; Kendrick, Lipids, 27:15 (1992)) and ATCC # 28211, ATCC # 20890, and ATCC # 20891. There are at least three different fermentation methods for commercial production of DHA: C. cohnii fermentation to produce DHASCO ™ (Martek Biosciences Corporation, Columbia, MD); previously known as DHAGold Fermentation of Schizochytrium species to produce oil (Martek Biosciences Co ); and fermentation of the Ulkenia species to produce DHActive ™ (Nutrinova, Frankfurt, Germany).

  Microbial production of PUFAs in microbial oils using recombinant means is expected to have several advantages over production from natural microbial sources. For example, the host's natural microbial fatty acid profile can be altered by the introduction of new biosynthetic pathways into the host and / or by suppression of undesired pathways, thereby allowing the desired PUFA (or its conjugated form) to Recombinant microorganisms with favorable characteristics for oil production can be used because they result in increased levels of production and decreased production of unwanted PUFAs. Second, the recombinant microorganism can provide PUFA in a specific form that may have a defined use. By further controlling the culture conditions, in particular by providing a specific substrate source for enzymes expressed by microorganisms, or by adding compound / genetic manipulation to suppress unwanted biochemical pathways, Microbial oil production can be manipulated. Thus, for example, the production of defined PUFAs (eg EPA) without altering the ratio of ω-3 and ω-6 fatty acids thus produced or significant accumulation of downstream or upstream products of other PUFAs Can be genetically manipulated.

Thus, for example, suitable PUFA biosynthetic pathway genes such as δ-4 desaturase, δ-5 desaturase, δ-6 desaturase, δ-12 desaturase, δ-15 desaturase, δ-17 desaturase, δ-9 desaturase, δ- 8 desaturase, [delta]-9 _{elongase, C 14/16 elongase, C 16/18 elongase,} by introducing a defined combination of _{C 18/20} elongase and _{C 20/22} elongase, a microorganism lacking the natural ability to produce EPA Can be engineered to express the PUFA biosynthetic pathway, but the specific enzymes introduced (and the genes encoding those enzymes) should not be recognized as limiting the invention in any way. is there.

  As an example, some yeasts have been genetically engineered to produce at least one PUFA. For example, Saccharomyces cerevisiae (Dyer, JM et al., Appl. Envi. Microbiol., 59: 224-230 (2002); Domergue, F. et al., Eur. J. Biochem. 269: 4105-4113 (2002); U.S. Patent No. 6,136,574; U.S. Patent Application Publication No. 2006-0051847-A1) and oily yeast Yarrowia lipolytica (U.S. Patent No. No. 7,238,482; U.S. Pat. No. 7,465,564; U.S. Pat. No. 7,588,931; U.S. Pat. No. 7,932,077; U.S. Pat. No. 550,286 ; Study reference in U.S. Patent Application Publication No. 2010-0317072-A1); U.S. Patent Application Publication No. 2009-0093543-A1 Pat.

  In some embodiments, benefits are recognized when the microbial host cell is oily. The oleaginous yeast is naturally capable of oil synthesis and accumulation, and the total oil content is greater than about 25% of the cell dry weight, more preferably greater than about 30% of the cell dry weight, most preferably It may comprise more than about 40% of the cell dry weight. In an alternative embodiment, for example, a yeast, for example a non-oleaginous yeast such as Saccharomyces cerevisiae, may be genetically engineered to make it oily so that it can produce more than 25% of the cell dry weight. Yes (International Publication No. 2006/102342 pamphlet).

  The genus typically identified as oleaginous yeast includes, but is not limited to, Yarrowia, Candida, Rhodotorula, Rhodosporium, Cryptococcus, Trichospolone ( Trichosporon and Lipomyces are included. More specifically, exemplary oil-synthesizing yeasts include Rhodosporidium toruloides, Lipomyces starkeyii, L. et al. L. lipoferus, Candida revkaufi, C.I. C. pulcherrima, C.I. C. tropicalis, C.I. C. utilis, Trichosporon pullans, T. T. cutaneum, Rhodotorula glutinus, R. R. graminis, and Yarrowia lipolytica (previously classified as Candida lipolytica).

  Most preferred is the oleaginous yeast Yarrowia lipolytica; in a further embodiment, most preferred are ATCC # 20362, ATCC # 8862, ATCC # 18944, ATCC # 76982 and / or LGAMS (7) 1 and Y. It is a lipolytica strain (Papanikolouou S., and Aggelis G., Bioresource. Technol. 82 (1): 43-49 (2002)).

  In some embodiments, it may be desirable that the oleaginous yeast is capable of “high level PUFA production” and the organism has at least about 5-10% of the desired PUFA (ie, LA, ALA, EDA) of total lipids. , GLA, STA, ETrA, DGLA, ETA, ARA, DPAn-6, EPA, DPAn-3 and / or DHA). More preferably, the oleaginous yeast produces the desired PUFA of at least about 10-70% of the total lipid. The structural form of the PUFA is not limited, but preferably the TAG includes PUFA.

  Accordingly, the PUFA biosynthetic pathway genes and gene products described herein are produced in wild-type or heterologous microbial host cells, particularly oleaginous yeast cells (eg, Yarrowia lipolytica). be able to. Expression in a recombinant microbial host modulates an existing PUFA pathway in the host to produce various PUFA pathway intermediates or to synthesize new products that were not previously possible using the host. It can be useful to rate.

Although many oleaginous yeasts can be genetically engineered for preferred ω-3 / ω-6 PUFA production based on the cited teaching provided above, the typical PUFA producing strain of oleaginous yeast, Yarrowia lipolytica (Yarlowia) Lipolytica) is described in Table 5. These strains include the following PUFA biosynthetic pathway genes: δ-4 desaturase, δ-5 desaturase, δ-6 desaturase, δ-12 desaturase, δ-15 desaturase, δ-17 desaturase, δ-9 desaturase, δ- 8 desaturase, δ-9 elongase, C _14/16 elongase, C _16/18 elongase, C _18/2
0 elongases, and various combinations of C _20/22 elongases, but the specific enzymes introduced (and the genes that encode them) and the specific PUFAs that are produced are in no way limiting the invention It should be recognized that there is no.

Since means for introducing the PUFA biosynthetic pathway into oleaginous yeast are well known, those skilled in the art will recognize that the methodology of the present invention is also demonstrated in the Yarrowia lipolytica strains described above (ie Yarrowia Lipitica
ia lipolytica)) or genus (ie Yarrowia). Rather, it produces microbial oils (preferably including PUFAs, eg LA, GLA, EDA, DGLA, ARA, DTA, DPAn-6, ALA, STA, ETrA, ETA, EPA, DPAn-3, DHA) Any oleaginous yeast or any other suitable microorganism that can be equally suitable for use in the methodology as demonstrated in Example 26 (but for each new microorganism to be treated, for example, Some process optimization may be required based on the difference in cell wall composition of each oil-bearing microorganism).

  Under conditions in which lipids are produced by microorganisms, microorganism species that produce lipids, preferably containing PUFAs, can be cultured and grown in the fermentation medium. Typically, the microorganisms are fed with carbon and nitrogen sources along with a number of additional chemicals or substances that allow the microorganisms to grow and / or produce microbial oils, preferably including PUFAs. Fermentation conditions depend on the microorganism used and can be optimized to achieve high PUFA content in the resulting biomass, as described in the above citation.

  In general, the type and amount of carbon source, the type and amount of nitrogen source, the ratio of carbon to nitrogen, the amount of different inorganic ions, oxygen level, growth temperature, pH, length of biomass production phase, length of oil accumulation phase, and By modifying the time and method of cell recovery, medium conditions can be optimized. For example, Yarrowia lipolytica is commonly used in complex media, such as yeast extract-peptone-dextrose broth (YPD), or limited minimal media (eg, lacking the components necessary for growth, and thereby Grow in yeast nitrogen basic medium (DIFCO Laboratories, Detroit, IM), which forces the selection of the desired recombinant expression cassette to allow production.

  Preferably, when the desired amount of microbial oil containing PUFA is produced by the microorganism, the fermentation medium can be mechanically processed to obtain untreated microbial biomass containing microbial oil. For example, the fermentation medium can be filtered or otherwise processed to remove at least a portion of the aqueous component (eg, by drying). As will be appreciated by those skilled in the art, untreated microbial biomass typically includes water. Preferably, after microbial fermentation, a portion of the water is removed from the untreated microbial biomass to a moisture level of less than 10 wt%, more preferably less than 5 wt%, most preferably less than 3 wt%. A microbial biomass having a moisture level is provided. The moisture level of microbial biomass can be controlled during drying. Preferably, the microbial biomass has a moisture level in the range of about 1 to 10 weight percent.

  Optionally, the fermentation medium and / or microbial biomass can be pasteurized or treated by other means to reduce the activity of endogenous microbial enzymes that can damage microbial oils and / or PUFA products.

  Thus, microbial biomass can be in the form of whole cells, whole cell lysates, homogenized cells, partially hydrolyzed cellular material, and / or disrupted cells (ie, disrupted microbial biomass).

  Microbial biomass can be mechanically processed to disrupt the biomass, for example via cell lysis or via physical means such as bead beaters, screw extrusion, etc. to provide greater access to the cell contents can do.

  The crushed microbial biomass has a crushing efficiency of at least 50% of the oil-containing microorganism. More preferably, the crushing efficiency is at least 75% of the oil-containing microorganisms, more preferably at least 80%, most preferably 85-90% or more. While the preferred range is described above, useful examples of crushing efficiency include any integer percentage from 50% to 100%, such as 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58% %, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91% , 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99% crushing efficiency.

The crushing efficiency is qualitatively measured by optical visualization or the following formula:% crushing efficiency = (% free oil ^* 100) divided by (% total oil) (% free oil and% total oil are solids Refers to the percentage of the cell wall that was broken or ruptured during processing, measured quantitatively according to (measured for the pellet).

  Solid pellets that have not been subjected to crushing (eg, screw extrusion, expellers, pistons, bead beaters, mortar and pestle, hammer milling, air jet milling, etc., eg, mechanical crushing) are typical Has low crushing efficiency. This is because fatty acids and release in the DAG, MAG and TAG, phosphatidylcholine and phosphatidylethanolamine fractions until the disruption process destroys both the inner wall of various organelles, including the membrane surrounding the cell wall and fat pad. This is because fatty acids are generally not extractable from microbial biomass. Different crushing processes result in different crushing efficiencies based on the specific shear, compression, static and dynamic forces inherently generated in the process.

  Increasing the disruption efficiency of microbial biomass typically results in increased extraction yield (eg, measured by weight percent of crude extract oil) because many of the microbial oils along with cell wall and membrane disruption This is because the possibility of being affected by the presence of the extraction solvent is high.

  Although various devices can be used to produce crushed microbial biomass, preferably the crushing is carried out in a twin screw extruder. More specifically, the twin screw extruder preferably has (i) about 0.04 to 0.4 KW / (kg / hr), more preferably 0.05 to 0.2 KW / (kg / hr). ), Most preferably, a total specific energy input (SEI) in the extruder of about 0.07 to 0.15 KW / (kg / hr); (ii) a consolidation zone using bushing elements having progressively shorter pitch lengths And (iii) including a compression band that uses flow restriction. Most of the mechanical energy required for cell disruption is applied in the compression zone and is created using flow restriction, for example in the form of a reverse screw element, restriction / blistering element or kneading element. The consolidation zone precedes the compression zone in the extruder. A first zone of the extruder may be present for feeding and transporting biomass into the consolidation zone.

  The pelleting process generally includes the following steps: (1) mixing microbial biomass and at least one oil-absorbable grinder to provide a crushed biomass mixture comprising crushed microbial biomass; (2) crushing biomass mixture Blending with at least one binder to provide a fixable mixture capable of forming solid pellets; and (3) forming the fixable mixture into solid pellets to provide pelleted microbial biomass. including.

  First, microbial biomass having a certain moisture level and containing oil-bearing microorganisms is mixed with at least one oil-absorbing grinder to provide a crushed biomass mixture.

Oil-absorbing milling agents may have a Moh hardness of 2.0 to 6.0, preferably 2.0 to about 5.0; more preferably about 2.0 to 4.0; and American Society for Testing And Materials. It may be a particle having an oil absorption coefficient of 0.8 or higher, preferably 1.0 or higher, more preferably 1.3 or higher, measured according to (ASTM) Method D1483-60. Preferred grinding agents have a median particle size of about 2 to 20 microns, preferably about 7 to 10 microns; and the BET method (Brunauer, S. et al. J. Am. Chem. Soc., 60: 309 (1938). ) At least 1 m ² / g, preferably 2 to 100 m ² / g.

Preferred grinding agents are selected from the group consisting of silica and silicates. The term “silica” as used herein consists primarily of (at least 90% by weight, preferably at least 95% by weight) silicon and oxygen atoms, the ratio of about two oxygen atoms to one silicon atom. And thus refers to a solid chemical having the empirical formula of SiO ₂ . Silica includes, for example, precipitated silica, fumed silica, amorphous silica, diatomaceous silica, also known as diatomaceous earth, and silane-treated forms of those silicas. The term “silicate” refers to a solid chemical consisting primarily of (at least 90% by weight, preferably at least 95% by weight) silicon, oxygen atoms and at least one metal ion. The metal ion can be, for example, lithium, sodium, potassium, magnesium, calcium, aluminum, or a mixture thereof. Aluminum silicates in the form of natural and synthetic zeolites can be used. Other silicates that may be useful are calcium silicate, magnesium silicate, sodium silicate, and potassium silicate.

A preferred grinding agent is diatomaceous earth having a specific surface area of about 10-20 m ² / g and an oil absorption coefficient of 1.3 or more. A commercial source of a suitable oil-absorbable grinder is Celite 209 diatomaceous earth available from Celite Corporation, Lompoc, CA.

  Other milling agents can be poly (meth) acrylic acid and ionomers derived from partial and complete neutralization of poly (meth) acrylic acid with sodium or potassium bases. As used herein, the term (meth) acrylate means that the compound can be either acrylate, methacrylate, or a mixture of the two.

  The at least one grinding agent is about 1 to 20 weight percent based on the sum of components (a) microbial biomass, (b) grinding agent and (c) binder in the solid pellet, and more preferably 1 to 15 It is present in weight percent, most preferably from about 2 to 12 weight percent.

  Providing a crushed biomass mixture by mixing microbial biomass and an oil-absorbing grinder [step (1)] can be performed by any method known in the art to apply energy to the mixed medium. . Preferably, the mixing provides a crushed biomass mixture having a temperature of 90 ° C or lower, more preferably 70 ° C or lower.

  For example, the microbial biomass and grinding agent can be fed into a mixer, such as a single screw or twin screw extruder, stirrer, single screw or twin screw kneader, or Banbury mixer and added The process can be the addition of all components at one time or incremental addition in batch.

  Preferably, the mixing has a SEI of about 0.04 to 0.4 KW / (kg / hr), a compaction zone using a bushing element having a progressively shorter pitch length, and a compression zone using a flow restriction as described above. Performed in a twin screw extruder. Under these conditions, the initial microbial biomass can be whole dry cells, and the process of cell disruption that results in a disrupted microbial biomass having a disruption efficiency of at least 50% of the oleaginous microorganism can be achieved at the start of the mixing step or during the mixing step. That is, cell disruption and step (1) can be combined to produce a disrupted biomass mixture at the same time. The presence of the grinding agent improves cell disruption, but most cell disruption occurs as a result of the twin screw extruder itself.

  Thus, for clarity, cell disruption of microbial biomass can be carried out, for example, in the absence of a grinding agent in a twin screw extruder having the compression zone described above, and then the grinding agent and disrupted microbial biomass. Are mixed in a twin screw extruder or various other mixers to provide a crushed biomass mixture. Alternatively, cell disruption of microbial biomass can be carried out, for example, in the presence of a grinding agent in a twin screw extruder having a compression zone. In either case, however, cell disruption (ie, disruption efficiency) should be maximized if it is desired to maximize the yield of extracted oil from the oil-bearing microorganisms in subsequent process steps.

  The at least one binder is then blended with the crushed biomass mixture to provide a fixable mixture that can form solid pellets (ie, pelleted microbial biomass).

  Binders useful in the present invention include water-soluble or water-dispersible hydrophilic organic materials and hydrophilic inorganic materials. Preferred water soluble binders have a water solubility at 23 ° C. of at least 1 weight percent, preferably at least 2 weight percent, more preferably at least 5 weight percent.

The binder is preferably less than 1 × 10 ⁻³ mole fraction; preferably less than 1 × 10 ⁻⁴ , more preferably less than 1 × 10 ⁻⁵ , most preferably less than 1 × 10 ⁻⁶ mole fraction and above 500 bar and 40 ° C. It has solubility in critical fluid carbon dioxide. Solubility was measured in “Solubility in Supercritical Carbon Dioxide”, Ram Gupta and Jae-Jin Shim, Eds. , CRC (2007).

  The binder acts to preserve the integrity and size of the pellets formed from the pelletizing process, and further acts to reduce fines in further processing and transport of the pellets.

  Suitable organic binders include alkali metal carboxymethyl cellulose having a degree of substitution of 0.5 to 1; preferably polyethylene glycol and / or alkyl polyethoxylates having an average molecular weight of less than 1,000; phosphorylated starch; cellulose And starch ethers such as carboxymethyl starch, methylcellulose, hydroxyethylcellulose, hydroxypropylcellulose and corresponding cellulose mixed ethers; proteins including gelatin and casein; tragacanth, sodium and potassium alginate, guam arabic, tapioca, maltodextrose and Partially hydrolyzed starch containing dextrin, polysaccharides containing water-soluble starch; sucrose, invert sugar, glucose siroc And sugar containing molasses; poly (meth) acrylate, copolymers of acrylic acid with a compound containing maleic acid or a vinyl group, polyvinyl alcohol, synthetic water-soluble polymers comprising partially hydrolyzed polyvinyl acetate and polyvinyl pyrrolidone. When the above compounds contain free carboxyl groups, they are usually present in the form of their alkali metal salts, more particularly their sodium salts.

Phosphorylated starch is a starch derivative in which the hydroxyl group of the starch anhydroglucose unit is replaced by a --O--P (O) (OH) ₂ group, or a water-soluble salt thereof, more particularly an alkali metal salt such as sodium and Understood as potassium salt. The average degree of phosphorylation of starch is understood as the number of esterified oxygen atoms bearing phosphate groups per saccharide monomer of starch averaged over all saccharide units. The average degree of phosphorylation of the preferred starch phosphate is in the range of 1.5 to 2.5.

  Partially hydrolyzed starch in the context of the present invention is understood as an oligomer or polymer of carbohydrates obtainable by partial hydrolysis of starch using conventional eg acid or enzyme catalyzed processes. The partially hydrolyzed starch is preferably a hydrolysis product having an average molecular weight of 440 to 500,000. A polysaccharide having a dextrose equivalent (DE) of 0.5 to 40, more particularly 2 to 30, is preferred, and DE is a standard for the reducing effect of a polysaccharide by comparison with dextrose (having 100 DE, ie DE 100). It is a scale. It is possible to use both maltodextrin (DE3-20) and dry glucose syrup (DE20-37) and also so-called yellow and white dextrins having a relatively high average molecular weight of about 2,000 to 30,000 after phosphorylation. it can.

  A preferred class of binders is water and carbohydrates selected from the group consisting of sucrose, lactose, fructose, glucose, and soluble starch. Preferred binders have a melting point of at least 50 ° C, preferably at least 80 ° C, more preferably at least 100 ° C.

  Suitable inorganic binders include sodium silicate, bentonite, and magnesium oxide.

  Preferred binders are materials that are considered “food grade” or “generally recognized as safe” (GRAS).

  The binder is about 0.5 to 10 weight percent, preferably 1 to 10 weight percent, based on the sum of the components of (a) microbial biomass, (b) grinding agent and (c) binder in the solid pellet. More preferably, it is present at about 3 to 8 weight percent.

  As those skilled in the art will appreciate, a fixable mixture has a moisture level significantly higher than the moisture level of the final solid pellet to allow easy handling (eg, extruding the fixable mixture into a die). Have Thus, for example, a binder comprising a solution of sucrose and water can be added to the crushed biomass mixture in a manner that results in a fixable mixture having 0.5 to 20 weight percent water. However, when the fixable mixture is dried to form solid pellets, the final moisture level of the solid pellets is less than 5 weight percent water and sucrose is less than 10 weight percent.

  Blending at least one binder with the crushed biomass mixture to provide a fixable mixture [step (2)] is performed by any method that allows dissolution of the binder and blending with the crushed biomass mixture. And fixable mixtures can be provided. The term “fixable mixture” means that the mixture can form solid pellets upon removal of a solvent, such as water, in the drying process.

  The binder can be blended by various means. One method involves dissolving the binder in a solvent to provide a binder solution and then metering the binder solution into the crushed biomass mixture at a controlled rate. The preferred solvent is water, but other solvents such as ethanol, isopropanol, etc. can be advantageously used. Another method involves adding the binder as a solid or solution to the biomass / grinding agent at or during the beginning of the mixing step, ie, combining steps (1) and (2) simultaneously. If the binder is added as a solid, preferably there is sufficient moisture in the crushed biomass mixture to dissolve the binder during the blending process. A preferred blending method involves metering the binder solution at a controlled rate into the crushed biomass mixture in the extruder, preferably after the compression zone described above. Addition of the binder solution after the compression zone allows for rapid cooling of the crushed biomass mixture.

  Forming solid pellets containing pelleted microbial biomass from the fixable mixture [step (3)] can be carried out by various means known in the art. One method is to extrude the fixable mixture into a die, such as a dome crusher, to form a uniform diameter strand, which is dried on a vibrating or fluid bed dryer to break the strand and provide pellets. Including that. Pelleted microbial biomass is suitable for downstream oil extraction, transportation, or other purposes.

  The solid pellets disclosed herein are desirably non-sticky at room temperature. The majority of solid pellets can be packed together for days without decomposing together, without decomposition of the pellet structure. The majority of the pellet is desirably a free-flowing pelletized composition. Preferably, the pellets have an average diameter of about 0.5 to about 1.5 mm and an average length of about 2.0 to about 8.0 mm. Preferably, the solid pellet has a final moisture level of about 0.1% to 5.0%, more preferably in the range of about 0.5% to 3.0%. Increasing the moisture level of the final solid pellet can lead to difficulties during storage due to, for example, mold growth.

  Accordingly, the solid pellets preferably comprise (a) from about 70 to about 98.5 weight percent of crushed biomass containing oil-bearing microorganisms; (b) from about 1 to about 20 weight percent of an oil-absorbing grinder; and ( c) comprising about 0.5 to 10 weight percent binder, the weight percent being relative to the sum of (a), (b) and (c) in the solid pellet. The solid pellets may comprise 75 to 98 weight percent (a); 1 to 15 weight percent (b) and 1 to 10 weight percent (c); preferably, the pellet is 80 to 95 weight percent (A); 2 to 12 weight percent (b) and 3 to 8 weight percent (c).

  The pelletization methodology has proven to be effective, highly scalable, robust and user friendly while allowing production at relatively high yields and high throughput rates. Cell disruption using conventional techniques such as spray drying, use of high shear mixers, etc. has been found to be inadequate for yeast cell walls containing, for example, chitin. Current wet media mill crushing processes produced fines and colloidal contaminants, required additional separation steps and resulted in significant oil loss. In addition, the wet media milling process complicates downstream processing by introducing a liquid carrier (eg, isohexane or water) and requiring a solid-liquid separation process, with oil loss. The pelletization process described herein relies on the production of a crushed biomass mixture; however, advantageously, the pulverization is performed without requiring a liquid carrier. Furthermore, the presence of a grinding agent within the solid pellets appears to facilitate high levels of oil extraction. This supports operability and cycle time because the pellets remain durable throughout the extraction process.

  The pelleted microbial biomass is extracted with a solvent to provide extracted oil and extracted pellets (ie, “residual biomass” or “residual pellet”).

Oil extraction is performed via treatment with various organic solvents (eg hexane, isohexane), enzymatic extraction, osmotic shock, ultrasonic extraction, supercritical fluid extraction (eg CO ₂ extraction), saponification and combinations of these methods be able to.

  In one embodiment, the extraction is performed with an organic solvent to produce an extracted oil, which is degummed and optionally bleached prior to step (c) of distilling the extracted oil. More specifically, the crude oil can be degummed by separation of the precipitated gum from the oil following water or acid hydration of phospholipids and other polar and neutral fat complexes. Alternatively, phospholipids and other hydratable impurities can be removed by contacting the oil with a polar solvent, such as acetone, or via an enzymatic degumming process. The degummed oil can be further bleached using bleaching clay, silica or carbon to remove colored compounds and residual metals.

  In an alternative embodiment, the extraction is performed using supercritical conditions. Supercritical fluid (SCF) exhibits intermediate properties between gas and liquid. An important property of SCF is that the fluid density can be continuously varied from liquid-like to gas-like density by varying temperature or pressure, or a combination thereof. Similarly, various density dependent physical properties show similar continuous variation in this region. Some of these properties include, but are not limited to, solvent strength (proven by the solubility of various substances in the SCF medium), polarity, viscosity, diffusivity, heat capacity, thermal conductivity, isothermal compression. , Expandability, shrinkage, fluidity, and molecular packing. The density variation of SCF also affects the chemical potential of the solute and thus the reaction rate and equilibrium constant. Thus, the solvent environment in the SCF medium can be optimized for a given application by adjusting various density dependent fluid properties.

If the temperature and pressure of the system exceed the corresponding critical point values defined by the critical temperature (T _c ) and critical pressure (P _c ), the fluid is in the SCF state. For pure materials, T _c and P _c are the highest values at which the vapor and liquid phases can coexist. Beyond _Tc , no liquid forms for pure material regardless of the applied pressure. Similarly, P _c and critical molar volume are defined at this T _c corresponding to the state in which the vapor and liquid phases merge. Although more complex for multicomponent mixtures, the critical state of the mixture is similarly identified as a condition where the coexisting vapor and liquid phase properties are indistinguishable. For a discussion of supercritical fluids, see Kirk-Othmer Encycl. of Chem. Technology, 4 ^th ed. , Vol. 23, pg. 452-477, John Wiley & Sons, NY (1997).

Any suitable SCF or liquid solvent can be used in an oil extraction process, such as, but not limited to, separating solid oil from microbial biomass by contacting solid pellets with the solvent, CO ₂ , tetrafluoromethane, ethane, ethylene, propane, propylene, butane, isobutane, isobutene, pentane, hexane, cyclohexane, benzene, toluene, xylene, and mixtures thereof are included in all reagents and products. It must be active. Preferred solvents include CO ₂ or _C 3 -C ₆ alkanes. More preferred solvents, CO _2, pentane, butane, and propane. The most preferred solvent is a supercritical fluid solvent containing CO _2.

In a preferred embodiment, supercritical CO ₂ extraction is performed as disclosed in US 2011-0263709-A1. By applying this particular methodology, the pelleted microbial biomass is subjected to supercritical oil extraction conditions. Phospholipids (PL) remain in the residual biomass (ie, extracted residual pellets) while the resulting extract (ie, extract containing a lipid fraction that is substantially free of phospholipids) is fractionated at least once. An extract oil is produced that includes a refined lipid composition that may comprise neutral fat and / or free fatty acids (FFA) while being substantially free of PL. The refined lipid composition can enrich TAG (preferably comprising PUFA) relative to the oil composition of pelleted microbial biomass that has not been treated with a solvent. The refined lipid composition can be subjected to further purification to produce a refined oil.

In this method, the supercritical fluid comprising CO ₂ is at least as long as the presence or amount of additional solvent is not detrimental to the process, for example, unless the PL contained in the microbial biomass is solubilized during the primary extraction step. One additional solvent (ie, a co-solvent) can further be included, eg, one or more of the solvents listed above. However, polar co-solvents such as ethanol, methanol, acetone, etc. can be added to deliberately impart polarity to the solvent phase, enabling PL extraction from microbial biomass during optional secondary oil extraction. It can be isolated.

Solid pellets containing the oil-impregnated microbial biomass can be contacted with liquid or supercritical CO ₂ under suitable extraction conditions according to at least two methods to provide the extract and residual biomass. According to the first method of US 2011-0263709-A1, the contact of pelleted microbial biomass with CO ₂ is carried out under extraction conditions corresponding to an increase in solvent density, for example increased pressure and Performed multiple times under reduced temperature to obtain an extract containing the refined lipid composition where the lipid fraction is substantially free of PL. The refined lipid composition of the extract varies in the distribution of FFA, monoacylglycerol (MAG), diacylglycerol (DAG), and TAG according to their relative solubility, which corresponds to the selected extraction conditions for each of the multiple extractions Depends on the solvent density.

Alternatively, and according to the present method, in the second method of US Patent Application Publication No. 2011-0263709-A1, the pelleted microbial biomass is a lipid that is substantially free of solvents such as CO ₂ and PL. Contacting under selected extraction conditions to provide an extract containing fractions is followed by a series of multiple step pressure drop steps to provide a refined lipid composition. Each of these stepwise pressure drop steps is performed in a separator vessel under pressure and temperature conditions corresponding to a decrease in solvent density to isolate the liquid phase refined lipid composition, which can be, for example, a simple decane. Can be separated from the extracted phase. The provided refined lipid compositions vary in the distribution of FFA, MAG, DAG, and TAG according to their relative solubilities, depending on the solvent density corresponding to the staged sorter vessel selection conditions.

  The extracted oil having the refined lipid composition obtained using the second method may correspond to the extract obtained in the first method if the extraction conditions are adequately met. Thus, it is believed possible to illustrate refined lipid compositions that can be obtained as described herein through the performance of the first method.

According to this method, the solid pellet containing the oleo-broken microbial biomass is subjected to a temperature and pressure sufficient to obtain an extract comprising a solvent, for example liquid or SCF CO ₂ and a lipid fraction substantially free of PL, and Contact can be made at the contact time. The lipid fraction can include neutral fat (including, for example, TAG, DAG, and MAG) and FFA. Contact and fractionation temperatures are sufficient to provide liquid or SCF CO ₂ , within the thermal stability range of PUFA, and sufficient CO ₂ to solubilize TAG, DAG, MAG, and FFA. It can be chosen to provide density. In general, the contact and fractionation temperature can be from about 20 ° C. to about 100 ° C., such as from about 35 ° C. to about 100 ° C .; the pressure can be from about 60 bar to about 800 bar, such as from about 80 bar to about 600 bar. Sufficient contact time, and an appropriate CO ₂ to microbial biomass ratio, can be determined by creating an extraction curve for a particular sample of solid pellets. These extraction curves, temperature dependent pressure, CO ₂ flow rate and the variable element, for example, the extraction conditions in the form of the extent and microbial biomass of cell disruption. In one embodiment of the method, the solvent comprises liquid or supercritical fluid CO ₂ and the mass ratio of CO ₂ to microbial biomass is from about 20: 1 to about 70: 1, such as from about 20: 1 to about 50. : 1.

  The extract containing the lipid fraction substantially free of PL can then be fractionated to obtain an extract oil having a refined lipid composition comprising at least one PUFA, the refined lipid composition being treated with a solvent TAG is enriched against the oil composition of the pelleted microbial biomass that has not been done. The refined lipid composition may further comprise DAG, MAG, or combinations thereof. The refined lipid composition may further comprise FFA. Other refined lipid compositions that can be obtained separately or in combination in the fractionation step include TAG enriched products depleted of FFA, FFA enriched products depleted of TAG, MAG and / or DAG enriched FFA enriched product, MAG and / or DAG depleted FFA enriched product, MAG and / or DAG enriched TAG enriched product, and MAG and / or DAG depleted TAG enrichment Product is included. Depending on the fractionation conditions used, in one embodiment of the method, the refined lipid composition can deplete FFAs against the oil composition of the pelleted microbial biomass. In one embodiment, the refined lipid composition can be enriched with at least one PUFA relative to the oil composition of the pelleted microbial biomass. In one embodiment, the refined lipid composition can be enriched with at least one PUFA having 20 or more carbon atoms relative to the oil composition of the pelleted microbial biomass.

  Fractionation can be performed by changing the temperature, pressure, or temperature and pressure of the separation conditions. Fractionation includes several separation processes including, for example, continuous decompression of a supercritical fluid rich extract, a series of mixer settler stages or liquid or SCF solvent extraction in an extraction column, short path distillation, vacuum vapor stripping, or melt crystallization Can be implemented in one of these. The step of fractionating the extract can be repeated one or more times to provide additional refined lipid compositions.

For example, reducing the pressure of the extract decreases the solubility of the dissolved solute and forms a separate liquid phase in each separation vessel. The temperature of the extract fed to each separation vessel can be adjusted, for example, through the use of a heat exchanger, to provide the desired solvent density and corresponding solute solubility in each separation vessel. The initial extract consists of a complex mixture of various types of lipid components (eg, FFA, MAG, DAG, and TAG) that exhibit similar solubility parameters so that accurate separation of the various components is achieved. Rather, each refined lipid composition obtained in the fractionation step contains a product distribution. In general, however, smaller soluble compounds will condense in the first separation vessel operating at maximum pressure, and most soluble compounds will condense in the final separation vessel operating at lowest pressure. The final separation vessel reduces the pressure of the extract phase sufficiently to essentially remove the bulk of residual solute in the extract phase, and the relatively pure CO ₂ stream from the top of this vessel It can be recycled back into the container.

FIG. 2 schematically illustrates one embodiment of the extraction method herein. In FIG. 2, a stream 10 containing pelleted microbial biomass and a stream 38 containing CO ₂ enter the vessel 14. Stream 12 and stream 16 containing pelleted microbial biomass are shown flowing into vessel 18. Contact of the pelleted microbial biomass with CO ₂ containing at least one PUFA occurs in vessel 14 at initial temperature T ₁₄ and pressure P ₁₄ , and in vessel 18 at temperature T ₁₈ and pressure P ₁₈ . T _{14 is T 18} and may be the same or _{different; P 14 may} be the same or different and _{P 18.} The resulting mixture of equilibrated CO ₂ and extract exits vessel 14 as stream 16 and enters vessel 18 where further contact of biomass and CO ₂ occurs resulting in a substantially PL free lipid shown as stream 20. An extract containing the fraction is provided. Residual biomass (not shown) remains in containers 14 and 16. If desired, additional extraction vessels can be included in the process (not shown). Alternatively, this process may use only one extraction vessel if desired (not shown). The use of more than one extraction container can be advantageous. This is because it may allow continuous CO ₂ flow through the process by changing the relative order of solvent addition to the extraction vessel (not shown), and one or more extraction vessels may be lined up. From (not shown), for example, loaded with pelleted microbial biomass or removed residual biomass.

Downstream of the extraction vessel, two separation vessel vessels 22 and 28 arranged in parallel are shown, and the fractionation of the extract can be effected via step-wise depressurization, possibly for example in a heat exchanger (not shown) Perform by adjusting the temperature through use. If desired, additional separation vessels can be included in the process (not shown). It is shown that an extract comprising a lipid fraction substantially free of CO ₂ and PL flows into vessel 22 as stream 20. A container 22, the pressure P ₂₂ is lower than P _18, may be the temperature T ₂₂ is different and the same as the T _18; under the conditions of the working process, a separate liquid phase containing a smaller solubility of the lipid constituents It is formed. The separate liquid phase resulting from the fractionation of the extract is shown exiting vessel 22 as stream 24, which represents the first refined lipid composition. The residue extracts, shown as stream 26, is introduced into the next separation vessel 28, the pressure P ₂₈ is reduced as compared to P _22, the temperature T ₂₈ may not be the same as T _22. The operating conditions of the process allow the formation of a separate liquid phase in vessel 28, which is shown to exit separation vessel 28 as stream 30. Stream 30 represents the second refined lipid composition.

From vessel 28, the residual extract containing relatively pure CO ₂ , shown as stream 32, can be recycled to extraction vessel 14 and / or another extraction vessel (not shown). Recirculation of CO ₂ typically provides economic benefits compared to once-through CO ₂ use. The purge stream, shown as stream 34, can be used to remove volatile components that can be built up by continuous recycle of CO _{2 into} the process. Make-up CO ₂ can be added to offset the CO ₂ loss that occurs through the purge. Make-up CO ₂ can be added to the recycle CO ₂ stream shown in FIG. 2 by a make-up CO ₂ stream 8 added to stream 36 to provide a combined CO ₂ stream 38. Alternatively, additional CO ₂ can be added to vessel 14 and / or vessel 18 as a separate feed stream (not shown).

FIG. 3 schematically illustrates one embodiment of the extraction process of the method of the present invention. In FIG. 3, a stream 70 containing CO ₂ is introduced into an extraction vessel 76 containing pelletized microbial biomass (not shown). Optionally, providing a combination stream 74 containing cosolvent CO ₂ and the co-solvent is added using a pump (not shown) to the CO ₂ stream (stream shown as 72). If no cosolvent is used, stream 70 and stream 74 are identical and contain only CO ₂ . Contact of CO _{2 with} the pelleted microbial biomass comprising at least one PUFA occurs in vessel 76, and an extract containing a lipid fraction substantially free of PL is streamed from the vessel as CO ₂ solvent and optionally Remove with co-solvent. Residual biomass (not shown) remains in the extraction vessel. The extract containing the lipid fraction substantially free of PL can then be fractionated in at least one separation vessel as described above with reference to FIG. 2 or, optionally, substantially free of PL. The non-lipid fraction can be isolated from the extract by draining CO ₂ and optionally the co-solvent (not shown).

The residual biomass from the primary extraction contains PL. This residual biomass may be extracted a second time with a polar extraction solvent such as a polar organic solvent such as methylene chloride or CO ₂ and a polar co-solvent such as alcohol to obtain a neutral fat free PL fraction. it can. The polar solvent can include, for example, methanol, ethanol, 1-propanol, and / or 2-propanol. Residual biomass containing PL and the extracted PL fraction may be suitable for use as aquaculture feed.

CO ₂ based extraction processes described herein provide several advantages over conventional organic solvent based processes. For example, CO ₂ is non-toxic, non-flammable, environmentally friendly, readily available and inexpensive. CO ₂ (T _c = 31.1 ° C.) can extract thermally labile lipids from microbial biomass at a relatively low temperature to minimize lipolysis in oil. Extracted lipids can be isolated from the CO ₂ solvent by simply venting the CO ₂ from the pressurized extract rather than through a heat treatment to strip the organic solvent. The refined lipid fraction can be isolated from an extract containing a lipid fraction that is substantially free of PL. Residual microbial biomass containing PL is, for example, a marketable by-product for aquaculture feed. PL can be extracted from residual microbial biomass as a relatively pure byproduct depleted in neutral fat. Extracted neutral fat fraction that is substantially free of PL is fractionated into a lipid fraction enriched in FFA and DAG (TAG depleted) and substantially in contrast to a lipid fraction that is substantially free of PL. Refined lipid compositions can be produced that are enriched in TAG (FFA and DAG depleted) relative to the lipid fraction that does not contain PL.

  The distillation step includes at least one pass of extracted microbial oil (eg, a refined lipid composition) through a short path distillation (SPD) still. Commercially available SPD distillers are well known in the chemical engineering art. Suitable distillers are available from, for example, Pope Scientific (Saukville, WI). The SPD distiller includes an evaporator and a condenser. Typical distillation is controlled by evaporator temperature, condenser temperature, oil feed rate into the evaporator and evaporator vacuum level.

  As those skilled in the art will appreciate, the number of passes through the SPD still depends on the moisture level of the extracted oil. If the moisture content is low, a single pass through the SPD still may be sufficient.

  Preferably, however, the distillation is a multi-pass process involving two or more successive passes of the extracted oil (eg, refined lipid composition) via an SPD evaporator. The first pass is typically carried out at a relatively low surface temperature of the evaporator, for example about 100 to 150 ° C., under a pressure of about 1 to 50 torr, preferably about 5 to 30 torr. This results in dehydrated oil because residual water and low molecular weight organic material are distilled. The dehydrated oil is then passed through the distiller at higher and lower pressures in the evaporator to provide a distillate fraction and a TAG-containing fraction (ie, lipid-containing fraction) enriched in sterols.

  In some embodiments, the extracted oil comprises a sterol fraction that can be removed after distillation under SPD conditions. More specifically, if the extract oil contains a sterol fraction, at least one distillation under short path distillation conditions may result in a distillate fraction containing sterol and an extract oil that has not been subjected to short path distillation. This results in a lipid-containing fraction containing a reduced amount of sterol compared to the amount of sterol. As discussed above, the sterol fraction may comprise one or more sterols selected from the group consisting of stigmasterol, ergosterol, brassicasterol, campesterol, β-sitosterol and desmosterol.

  Additional passage of the TAG-containing lipid fraction can be done through a still to remove additional sterols. For each additional pass, the distillation temperature can be increased relative to the temperature of the previous distillation. Preferably, the reduction in the amount of sterol fraction is at least about 40% to 70%, preferably at least about 70% to 80%, more preferably about 80% compared to the sterol fraction of the sterol-containing microbial oil. Make enough passes to be super.

  Preferably, the SPD conditions comprise at least one pass of a sterol-containing microbial oil (ie, a refined lipid composition) at a vacuum level of 30 mTorr or less, preferably 5 mTorr or less. Preferably, the SPD conditions comprise at least one pass at about 220 to 300 ° C, preferably about 240 to 280 ° C.

Thus, for example, in one embodiment, the extracted oil is (i) enriched with TAG (relative to the oil composition of pelleted microbial biomass that has not been treated with a solvent), comprising at least one PUFA; ) A refined lipid composition comprising at least 300 mg / 100 g of sterol fraction. When subjected to at least one distillation under SPD conditions, the distillation is a reduced sterol fraction with improved clarity compared to a distillate fraction containing sterol and a refined lipid composition not subject to SPD. A lipid-containing fraction containing TAG having a fraction is generated. Improved clarity refers to a lack of turbidity or opacity of the oil. Sterol-containing microbial oils become cloudy when stored at temperatures below about 10 ° C. due to the reduced solubility of sterols in the oil at low temperatures. The evaporation process is such that the resulting lipid-containing fraction has a reduced amount of sterol present and thus remains clear or substantially clear upon storage at about 10 ° C. It acts to remove the target part. Test methods that can be used to evaluate the clear of oil, American Oil Chemists'Society (AOCS) Official Method Cc 11-53 ( "Cold Test", Official Methods and Recommended Practices of the AOCS, 6 th ed , Urbana, IL, AOCS, 2009, incorporated herein by reference).

  Surprisingly, the removal of sterols in the distillation process can be achieved without significant degradation of PUFAs, such as EPA rich oils. Oil degradation can be assessed based on PUFA content and chromatographic profiling (hereinafter demonstrated in Example 23).

  Collection of the lipid-containing fraction can be accomplished by diverting the fraction to a suitable container after completion of passage through the evaporator.

  The fatty acid in the extracted microbial oil or product thereof (eg, a lipid-containing fraction) is typically in a biological form, such as a triglyceride or phospholipid. Because it is difficult to enrich these forms of fatty acid profiles, the individual fatty acids of microbial oils are usually liberated by transesterification using techniques well known to those skilled in the art. Since the fatty acid ester mixture has substantially the same fatty acid profile as the microbial oil prior to transesterification, the product of the transesterification process is still typically considered as unconcentrated microbial oil (ie, ester form). .

  Enrichment of microbial oils containing 30 to 70% by weight of the desired PUFA, measured as% by weight of TFA (microbial oils are obtained from oleaginous microorganisms that accumulate in excess of 25% of dry cell weight as oil) Resulting in an oil concentrate (ie, “oil concentrate”), measured as weight percent of oil, containing at least 70% by weight of the desired PUFA. Specifically, the ethyl or other ester of the microbial oil is the desired PUFA (eg, LA, EDA, GLA, DGLA, ARA, DTA, DPAn-6, ALA, STA, ETrA, ETA, EPA, DPAn-3 , DHA), and methods commonly used in the art such as: fractional distillation, urea adduct formation, short path distillation, supercritical fluid fractionation using countercurrent columns, supercritical fluid chromatography, It can be separated by liquid chromatography, enzymatic separation and treatment with silver salts, simulated moving bed chromatography, actual moving bed chromatography and combinations thereof.

Thus, for example, a method of making an EPA concentrate comprising at least 70% by weight of EPA, measured as weight percent of oil, and substantially free of DHA:
a) transesterifying the lipid-containing fraction of the invention comprising 30 to 70% by weight of EPA, measured as wt% of TFA, and substantially free of DHA; and b) transesterification of step (a) Disclosed herein is a method comprising enriching an oil to obtain an EPA concentrate that is measured as oil weight percent and contains at least 70 weight percent EPA and is substantially free of DHA.

  For example, unconcentrated refined microbial oil (ie, a lipid-containing fraction) from Yarrowia lipolytica that contains 58.2% EPA, measured as weight percent of TFA, and is substantially free of DHA. Provided in Example 27 herein. This lipid-containing fraction contains 76.5% EPA-EE, as measured by weight% oil, of the resulting EPA ethyl ester (EPA-EE) concentrate via urea adduct formation in Example 28. Enrich to be substantially free of DHA. Similarly, Example 29 demonstrates enrichment of the same lipid-containing fraction via liquid chromatography, and the resulting EPA-EE concentrate is 82.8% or 95.4% measured as weight percent oil. % EPA-EE and substantially free of DHA. Example 30 demonstrates enrichment of the same lipid-containing fraction via supercritical fluid chromatography, containing 85% or 89.8% EPA-EE, measured as weight percent of oil, substantially DHA Results in an EPA concentrate free of

  Alternative unconcentrated SPD refined microbial oil (ie, lipid-containing fraction) from Yarrowia lipolytica containing 56.1% EPA, measured as wt% TFA, and substantially free of DHA Is provided in Example 31. The enrichment of this lipid-containing fraction in Example 32 is done via fractional distillation, thereby containing 73% EPA-EE, measured as weight percent of oil, and substantially free of DHA. Is generated. Fractionation advantageously removes much of the low molecular weight ethyl ester present in the oil (ie, but not exclusively, C18 in the lipid-containing fraction of Example 32). .

  An alternative unconcentrated SPD refined microbial oil (ie lipid) from Yarrowia lipolytica containing 54.7% EPA, measured as wt% TFA, and substantially free of DHA, NDPA and HPA Contained fraction) is provided in Example 34. The enrichment of this lipid-containing fraction is performed via fractional distillation and liquid chromatography, thereby containing 97.4% EPA-EE, measured as weight percent oil, substantially consisting of DHA, NDPA and HPA. To produce an EPA concentrate free of. Those skilled in the art will know enrichment processes (eg fractional distillation, urea adduct formation, short path distillation, supercritical fluid fractionation using a reverse flow column, supercritical fluid chromatography, liquid chromatography, enzymatic separation and treatment with silver salts, simulated It should be appreciated that other combinations of moving bed chromatography, actual moving bed chromatography) can be utilized to produce the EPA concentrates of the present invention.

  For example, it may be particularly advantageous to produce an EPA concentrate that contains at least 70% by weight of EPA, measured as weight% of oil, and is substantially free of DHA: Transesterification of lipid-containing fractions containing 30 to 70% by weight of EPA, measured as%; (b) Fractionation for removal of many of the low molecular weight ethyl esters, ie those containing C14, C16 and C18 fatty acids And (c) at least selected from the group consisting of urea adduct formation, liquid chromatography, supercritical fluid chromatography, simulated moving bed chromatography, actual moving bed chromatography and combinations thereof Includes one additional enrichment process. Low concentrations of C14, C16 and C18 fatty acids in the oil sample as a result of fractional distillation can facilitate the subsequent enrichment process.

  As will be appreciated by those skilled in the art, any of the above EPA concentrates in the ethyl ester form may optionally be in other forms, such as methyl esters, acids or triacylglycerides, or any other suitable form or combination thereof. Can be easily converted. Means of chemical conversion of one derivative of PUFA to another are well known. For example, triglycerides can be converted to the sodium salt of the cleaved acid by saponification and free fatty acids by acidification, and the ethyl ester can be reesterified to the triglyceride via glycerolysis. Thus, while the EPA concentrate is initially expected to be in the ethyl ester form, this is in no way limiting. Thus, at least 70% by weight EPA, measured as the weight percent of oil in the EPA concentrate, refers to EPA in the form of free fatty acids, triacylglycerols, esters, and combinations thereof, and esters are most preferably It is in the form of ethyl ester.

  One skilled in the art will recognize that the processing conditions to provide PUFA enrichment of any preferred level of lipid-containing fractions such that the desired PUFA concentrate has at least 70% by weight of the desired PUFA, measured as weight percent of oil. (But increased PUFA purity is often inversely proportional to PUFA yield). Accordingly, those skilled in the art would measure the desired PUFA weight percent as any integer percentage (or fraction thereof) from 70% to 100% (including 100%), ie, specifically, as a weight percent of oil. 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86 %, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% and 100% of the desired PUFA Recognize that.

  More specifically, in one embodiment of the present invention, an EPA concentrate is provided that comprises at least 80% by weight of EPA, measured as weight percent of oil, and is substantially free of DHA. In another embodiment, an EPA concentrate is provided that comprises at least 90% by weight of EPA, measured as weight percent of oil, and is substantially free of DHA. In yet another embodiment, an EPA concentrate is provided that comprises at least 95% by weight of EPA, measured as weight percent of oil, and is substantially free of DHA.

  In a preferred embodiment, the EPA concentrate comprises at least 70% by weight of EPA, measured as weight percent of oil, and is substantially free of DHA, substantially free of NDPA and substantially free of HPA. And can be further characterized.

  Although not limited to any particular application, the PUFA concentrates of the present invention are particularly well suited for pharmaceutical use. As is well known to those skilled in the art, PUFAs can be capsules, tablets, granules, powders that can be dispersed in beverages, or other solid oral dosage forms, liquids (eg, syrups), soft gel capsules, coats It can be administered in soft gel capsules or other conventional dosage forms such as oral liquids in capsules. Capsules can be hard or soft shelled and can be of gelatin or veterinary source. The PUFA can also be contained in a liquid suitable for injection or infusion.

  In addition, PUFAs can be administered by a combination of one or more non-active pharmaceutical ingredients (commonly known herein as “excipients”). Non-active ingredients are, for example, solubilized, suspended, thickened, diluted, emulsified, stabilized, stored, protected, active ingredients safe and convenient, otherwise acceptable and usable in an acceptable formulation. Functions to color, flavor and adapt.

  Excipients include, but are not limited to, surfactants such as propylene glycol monocaprylate, mixtures of glycerol and polyethylene glycol esters of long chain fatty acids, polyethoxylated castor oil, glycerol esters, oleoyl macrogol glycerides , Propylene glycol monolaurate, propylene glycol dicaprylate / dicaprate, polyethylene-polypropylene glycol copolymer and polyoxyethylene sorbitan monooleate, cosolvents such as ethanol, glycerol, polyethylene glycol, and propylene glycol, and oils such as palm Oil, olive oil or safflower oil may be included. Since the use of surfactants, co-solvents, oils or combinations thereof is generally known in the pharmaceutical arts and as will be understood by those skilled in the art, any suitable surfactant may be used in the invention and embodiments thereof Can be used at the same time.

  The dose concentration of the composition, the dose schedule and the duration of administration should be sufficient for the onset of the intended effect, eg adjusted appropriately depending on the dosage form, route of administration, severity of symptoms, weight, age, etc. can do. While the composition can be administered orally, it can be administered in three divided doses per day, although the composition can alternatively be administered in a single dose or in several divided doses.

  Extract oil compositions comprising at least one PUFA, such as EPA (or derivatives thereof), have well-known clinical and pharmaceutical values. For example, see US Patent Application Publication No. 2009-0093543A1. For example, a lipid composition comprising PUFA can be used as a meal substitute or supplement, in particular a special formula, for patients receiving intravenous nutrition or to prevent or treat malnutrition. Alternatively, purified PUFA (or a derivative thereof) can be incorporated into an edible oil, fat or margarine formulated to receive the desired amount for dietary supplementation in normal use by the recipient. PUFAs can also be incorporated into special formulas, nutritional supplements or other foods and can be used as anti-inflammatory or cholesterol lowering agents. Optionally, the composition can be used for either human or animal pharmaceutical use.

  Supplementation of human or animal PUFAs can result in increased levels of added PUFAs and their metabolic consequences. For example, treatment with EPA can result in not only increased levels of EPA, but also increased levels of downstream products of EPA, such as eicosanoids (ie, prostaglandins, leukotrienes, thromboxanes), DPAn-3 and DHA. Complex regulatory mechanisms are desirable to combine various PUFAs or add different conjugates of PUFAs to prevent, control or overcome such mechanisms to achieve the desired level of defined PUFAs in an individual. Can do.

  Alternatively, PUFA, or a derivative thereof, can be utilized in the synthesis of animal and aquatic feeds such as dry feed, semi-moist and wet feed. This is because these formulations generally require that at least 1-2% of the nutritional composition is omega-3 and / or omega-6 PUFA.

  The invention is further defined in the following examples. It should be understood that these examples are given by way of illustration only, while illustrating preferred embodiments of the present invention. From the above discussion and these examples, those skilled in the art will recognize the essential features of the invention and make various changes and modifications to the invention without departing from its spirit and scope. Can be adapted.

The following abbreviations are used:
“HPLC” is high performance liquid chromatography, “ASTM” is American Society for Testing And Materials, “C” is Celsius, “kPa” is kilopascals, “mm” is millimeters, “Μm” is micrometer, “μL” is microliter, “mL” is milliliter, “L” is liter, “min” is minutes, “mM” is millimolar , “MTorr” is milliTorr, “cm” is centimeter, “g” is gram, “wt” is weight, “h” or “hr” is time, “temp” Or “T” is temperature, “SS” is stainless steel, “in” is inches, “id” is the inner diameter "O.d." is the outer diameter.

Materials Biomass Preparation Yarrowia lipolytica yeast strains that produce various amounts of microbial oil containing PUFA are described below. Biomass was obtained in a two-stage fed-batch fermentation process and then subjected to downstream processing as described below.

  Yarrowia lipolytica strain: The production of Yarrowia lipolytica strain Y8672 is described in US Patent Application Publication No. 2010-0317072-A1. The Y8672 strain derived from Y. lipolytica ATCC # 20362 can produce about 61.8% EPA to total lipids via expression of the δ-9 elongase / δ-8 desaturase pathway. It was.

  The final genotype of the Y8672 strain against wild type Yarrowia lipolytica ATCC # 20362 is Ura +, Pex3-, unknown1-, unknown2-, unknown4-, unknown5-, unknown-7, unknown, Leu +, Lys +, YAT1 :: ME3S :: Pex16, GPD :: ME3S :: Pex20, GPD :: FmD12 :: Pex20, YAT1 :: FmD12 :: Oct, EXP1 :: FmD12S :: ACO, GPAT :: EgD9e :: Lip2, FBAINm :: EgD9eS :: Lip2, EXP1 :: EgD9eS :: Lip1, YAT1 :: EgD9eS :: Lip2, FB INm :: EgD8M :: Pex20, FBAIN :: EgD8M :: Lip1, EXP1 :: EgD8M :: Pex16, GPD :: EaD8S :: Pex16 (2 copies), YAT1 :: E389D9eS / EgD8M :: Lip1, YAT1 :: Eg9 / EgD8M :: Aco, FBAIN :: EgD5SM :: Pex20, YAT1 :: EgD5SM :: Aco, GPM :: EgD5SM :: Oct, EXP1 :: EgD5M :: Pex16, EXP1 :: EgD5SM :: Lip1, YAT1 :: EaDSM :: Oct, YAT1 :: PaD17S :: Lip1, EXP1 :: PaD17 :: Pex16, FBAINm :: PaD17 :: Aco, GPD :: YlCPT1 :: Aco, and YAT1 :: MCS :: Li p1.

The structure of the expression cassette is represented by a simplified notation system “X :: Y :: Z”, where X describes a promoter fragment, Y describes a gene fragment, Z describes a terminator fragment, Operatively connected to each other. Abbreviations are as follows: FmD12 is the Fusarium moniliform δ-12 desaturase gene [US Pat. No. 7,504,259]; Codon-optimized δ-12 desaturase gene derived from F. moniliform [US Pat. No. 7,504,259]; ME3S is Mortierella alpina [US Pat. No. 7,470]. , 532] codon-optimized C _16/18 elongase gene; EgD9e is the Euglena gracilis δ-9 elongase gene [US Pat. No. 7,645,604]. Yes; EgD9eS is E.D. A codon-optimized δ-9 elongase gene derived from E. gracilis [US Pat. No. 7,645,604]; A synthetic mutant δ-8 desaturase gene [US Pat. No. 7,709,239] derived from E. gracilis [US Pat. No. 7,256,033]; EaD8S is E389D9eS / EgD8M is a Eutroptiella sp. CCMP389 δ-9 elongase (Euglena Anabena) [U.S. Pat. No. 7,790,156] is a codon optimized δ-8 desaturase gene; Codon-optimized δ-9 elongase gene (“E389D9eS”) from US Pat. No. 7,645,604) and δ-8 desaturase “EgD8M” (supra) [US Patent Application Publication No. 2008-0254191. -A1 specification] EgD9ES / EgD8M is a δ-9 elongase “EgD9eS” (supra) and a δ-8 desaturase “EgD8M” (supra) [US Patent Application Publication No. 2008-0254191-A1. DGLA synthase produced by ligation of EgD5M and EgD5SM. A synthetic mutant δ-5 desaturase gene derived from E. gracilis [US Pat. No. 7,678,560] [US Patent Application Publication No. 2010-0075386-A1]; EaD5SM E. A synthetic mutant δ-5 desaturase gene derived from E. Annabaena [US Pat. No. 7,943,365] [US Patent Application Publication No. 2010-0075386-A1]; PaD17 Is the Pythium aphanidermatum δ-17 desaturase gene [US Pat. No. 7,556,949]; A codon-optimized δ-17 desaturase gene derived from P. aphanidermatum [US Pat. No. 7,556,949]; Y. lipolytica diacylglycerol choline phosphotransferase gene [US Pat. No. 7,932,077]; MCS is Rhizobium leguminosarum bv. Codon-optimized malonyl-CoA synthetase gene derived from Viciae 3841 [US Patent Application Publication No. 2010-0159558-A1].

  For a detailed analysis of the total lipid content and composition of the Y8672 strain, a flask assay was performed in which cells were grown in two stages for a total of 7 days. Based on the analysis, the Y8672 strain produced a dry cell weight of 3.3 g / L [“DCW”], the total lipid content of the cells was 26.5 [“TFA% DCW”], and the dry cell weight of The EPA content as a percentage [“EPA% DCW”] was 16.4 and the lipid profile with the respective fatty acid concentration as the weight percent of TFA [“% TFA”] was as follows: 16: 0 (Palmitate) is 2.3, 16: 1 (palmitoleic acid) is 0.4, 18: 0 (stearic acid) is 2.0, 18: 1 (oleic acid) is 4.0, 18: 2 (LA) 16.1, ALA 1.4, EDA 1.8, DGLA 1.6, ARA 0.7, ETrA 0.4, ETA 1.1, EPA 61.8, others 6 .4.

  The production of Yarrowia lipolytica strain Y9502 is described in US Patent Application Publication No. 2010-0317072-A1, which is incorporated herein by reference in its entirety. The Y9502 strain derived from Y. lipolytica ATCC # 20362 can produce about 57.0% EPA with respect to total lipids via expression of the δ-9 elongase / δ-8 desaturase pathway. It was.

  The final genotype of strain Y9502 against wild-type Y. lipolytica ATCC # 20362 is Ura +, Pex3-, unknown1-, unknown2-, unknown4-, unknown5-, unknown6-, unknown7-, unknown8- , Unknown9-, unknown10-, YAT1 :: ME3S :: Pex16, GPD :: ME3S :: Pex20, YAT1 :: ME3S :: Lip1, FBAINm :: EgD9eS :: Lip2, EXP1 :: EgD9eS :: Lip1, GPAT: EgD9e :: Lip2, YAT1 :: EgD9eS :: Lip2, FBAINm :: EgD8M :: Pex20, EXP1 :: EgD8M :: Pex1 , FBAIN :: EgD8M :: Lip1, GPD :: EaD8S :: Pex16 (2 copies), YAT1 :: E389D9eS / EgD8M :: Lip1, YAT1 :: EgD9eS / EgD8M :: Aco, FBAINm :: EaD9eS: EaD8: S , GPD :: FmD12 :: Pex20, YAT1 :: FmD12 :: Oct, EXP1 :: FmD12S :: Aco, GPIN :: FmD12 :: Pex16, EXP1 :: EgD5M :: Pex16, FBAIN :: EgD5SM :: Pex20, GPIN :: EgD5SM :: Aco, GPM :: EgD5SM :: Oct, EXP1 :: EgD5SM :: Lip1, YAT1 :: EaD5SM :: Oct, FBAINm :: PaD17 :: Aco, EXP1: PaD17 :: Pex16, YAT1 :: PaD17S :: Lip1, YAT1 :: YICPT :: Aco, YAT1 :: was MCS :: Lip1, FBA :: MCS :: Lip1, YAT1 :: MaLPAAT1S :: Pex16.

  Abbreviations not defined above are as follows: EaD9eS / EgD8M is a codon optimized δ-9 derived from Euglena anabena δ-9 elongase [US Pat. No. 7,794,701]. MaLPAAT1S is a DGLA synthase produced by linking an elongase gene (“EaD9eS”) and a δ-8 desaturase “EgD8M” (supra) [US Patent Application Publication No. 2008-0254191-A1]; Codon-optimized lysophosphatidic acid acyltransferase gene derived from Mortierella alpina (US Pat. No. 7,879,591).

  For a detailed analysis of the total lipid content and composition of the Y9502 strain, a flask assay was performed in which cells were grown in two stages for a total of 7 days. Based on the analysis, the Y9502 strain produced a dry cell weight [“DCW”] of 3.8 g / L, the total lipid content of the cells was 37.1 [“TFA% DCW”], The EPA content as a percentage [“EPA% DCW”] was 21.3, and the lipid profile with the respective fatty acid concentration as the weight percent of TFA [“% TFA”] was as follows: 16: 0 (Palmitate) is 2.5, 16: 1 (palmitoleic acid) is 0.5, 18: 0 (stearic acid) is 2.9, 18: 1 (oleic acid) is 5.0, 18: 2 (LA) 12.7, ALA 0.9, EDA 3.5, DGLA 3.3, ARA 0.8, ETrA 0.7, ETA 2.4, EPA 57.0, others 7 .5.

  Total derived from Y. lipolytica ATCC # 20362 and having a total lipid content [“TFA% DCW”] of 28-32% via expression of the δ-9 elongase / δ-8 desaturase pathway The production of Yarrowia lipolytica strain Y4305F1B1 capable of producing about 50-52% EPA with respect to lipid is described in US Patent Application Publication No. 2011-0059204-A1, which is incorporated herein by reference in its entirety. It is described in the specification. Specifically, the Y4305F1B1 strain has been previously described in Y. Lipolytica (Y.P.) as previously described in US 2008-0254191 (General Methods), the disclosure of which is incorporated herein in its entirety. lipolytica) derived from the Y4305 strain.

  The final genotype of the Y4305 strain against wild-type Y. lipolytica ATCC # 20362 is SCP2- (YALI0E01298g), YALI0C18711g-, Pex10-, YALI0F24167g-, unknown1-, unknPD8: munkPD8: :: Pex20, YAT1 :: FmD12 :: OCT, GPM / FBAIN :: FmD12S :: OCT, EXP1 :: FmD12S :: Aco, YAT1 :: FmD12S :: Lip2, YAT1 :: ME3S :: Pex16, EXP1 :: ME3S :: Pex20 (3 copies), GPAT :: EgD9e :: Lip2, EXP1 :: EgD9eS :: Lip1, FBAINm :: EgD9eS :: Lip2 FBA :: EgD9eS :: Pex20, GPD :: EgD9eS :: Lip2, YAT1 :: EgD9eS :: Lip2, YAT1 :: E389D9eS :: OCT, FBAINm :: EgD8M :: Pex20, FBAIN :: EgD8M :: Lip1 ), EXP1 :: EgD8M :: Pex16, GPIN :: EgD8M :: Lip1, YAT1 :: EgD8M :: Aco, FBAIN :: EgD5 :: Aco, EXP1 :: EgD5S :: Pex20, YAT1 :: EgD5S :: Aco, EXP1 :: EgD5S :: ACO, YAT1 :: RD5S :: OCT, YAT1 :: PaD17S :: Lip1, EXP1 :: PaD17 :: Pex16, FBAINm :: PaD17 :: Aco, YAT1 :: YlCPT1 : ACO, was GPD :: YlCPT1 :: ACO.

  Abbreviations not defined above are as follows: EgD5 is Euglena gracilis δ-5 desaturase [US Pat. No. 7,678,560]; Codon-optimized δ-5 desaturase gene from E. gracilis [US Pat. No. 7,678,560]; RD5S is a Peridinium sp. CCMP 626 [US Pat. 695,950]] is a codon optimized δ-5 desaturase.

  The total lipid content of Y4305 cells is 27.5 [“TFA% DCW”], the lipid profile is as follows, and the concentration of each fatty acid is as a weight percent of TFA [“% TFA”]: 16: 0 (palmitate) is 2.8, 16: 1 (palmitoleic acid) is 0.7, 18: 0 (stearic acid) is 1.3, 18: 1 (oleic acid) is 4.9, 18 : 2 (LA) is 17.6, ALA is 2.3, EDA is 3.4, DGLA is 2.0, ARA is 0.6, ETA is 1.7, and EPA is 53.2.

Strain Y4305 was subjected to transformation with a dominant non-antibiotic marker for Y. lipolytica based on sulfonylurea [“SU ^R ”] resistance. More specifically, the marker gene is a single amino acid change conferring sulfonylurea herbicide resistance, ie natural acetohydroxyacid synthase (“AHAS” or acetolactate synthase with W497L; EC 4.1. 3.18) (SEQ ID NO: 292 of WO 2006/052870 pamphlet). As described in U.S. Patent Application Publication No. 2011-0059204-A1, using random integration into SU ^R gene Yarrowia lipolytica marker (Yarrowia) Y4305 strain in an oily conditions to the parent Y4305 strain Cells with increased lipid content were identified when grown on.

When evaluated under 2 liter fermentation conditions, the average EPA production rate [“EPA% DCW”] for the Y4305 strain was 50-56 compared to 50-52 for the mutant SU ^R Y4305-F1B1 strain. It was. The average lipid content [“TFA% DCW”] for the Y4305 strain was 20-25 compared to 28-32 for the Y4305-F1B1 strain. Thus, lipid content increased by 29-38% for the Y4503-F1B1 strain with minimal impact on EPA production rate.

  Fermentation: In a shake flask, Y. Inoculum was prepared from a frozen culture of lipolytica (Y. lipolytica). After the incubation period, the culture was used to inoculate a seed fermentor. When the seed culture reached the appropriate target cell density, it was then used to inoculate a larger fermentor. Fermentation is a two-stage fed-batch process. In the first stage, yeast was cultured under conditions that promote rapid growth to high cell density; the culture medium contained glucose, various nitrogen sources, trace metals, and vitamins. In the second stage, the yeast was nitrogen starved and glucose was fed continuously to promote lipid and PUFA accumulation. Monitor and control process variables including temperature (controlled to 30-32 ° C.), pH (controlled to 5-7), dissolved oxygen concentration and glucose concentration for standard operating conditions to ensure consistent process performance and final PUFA oil quality Secured.

  One skilled in the art of fermentation knows that the oil profile of a defined Yarrowia strain varies depending on the fermentation run itself, medium conditions, process parameters, scale-up, etc., as well as the particular time point at which the culture is sampled ( For example, see US Patent Application Publication No. 2009-0093543-A1).

  Downstream processing: Antioxidants were optionally added to the fermentation broth before processing to ensure oxidative stability of the EPA oil. Yeast biomass was dehydrated and washed to remove salt and residual media to minimize lipase activity. Then either drum drying (typically with 80 psig steam) or spray drying was performed to reduce the moisture level to less than 5% to ensure oil stability during short term storage and shipping. Drum-dried flakes having a particle size distribution in the range of about 10 to 100 microns, or spray-dried powder, were used as the first “microbial biomass with oil-bearing microorganisms” in the following comparative examples and examples.

  Grinding agent: Celite 209 diatomaceous earth is available from Celite Corporation, Lompoc, CA. Celato MN-4 diatomaceous earth is available from EP Minerals, An Eagle Pitcher Company, Reno, NV.

  Other materials: All commercially available reagents were used as they were. All solvents used were HPLC grade. Acetyl chloride was 99 +%. TLC plates and solvents were obtained from VWR (West Chester, PA). HPLC or SCF grade carbon dioxide was obtained from MG Industries (Malvern, PA).

Twin Screw Extrusion Method Twin screw extrusion was used in crushing dry yeast biomass using a grinding agent and preparing a crushed biomass mixture.

  Dry yeast is fed into an extruder, preferably a twin screw extruder having a suitable length to achieve the following operations, usually 21-39 L / D. The first section of the extruder is used to feed and transport the material. The second section is a consolidation zone designed to consolidate and compress the feed using bushing elements having progressively shorter pitch lengths. The consolidation zone is followed by a compression zone that functions to impart most of the mechanical energy required for cell disruption. This zone is created using a flow restriction in the form of a reverse screw element, restriction / blistering element or kneading element. When preparing crushed biomass, a grinding agent (eg, diatomaceous earth) is typically fed simultaneously with the microbial biomass feed and both through the compression / consolidation zone, thus improving the level of crushing. After the compression zone, a binder (eg, a water / sucrose solution) is added via the liquid injection port and mixed in subsequent mixing compartments consisting of various combinations of mixing elements. The final mixture (ie, “fixable mixture”) is discharged through a final barrel that opens at the end, thus causing little or no back pressure in the extruder. The fixable mixture is then fed to a dome crusher and either a vibrating or fluid bed dryer. This results in a pelletized material (ie, solid pellets) suitable for downstream oil extraction.

The SCF extract dried and mechanically disrupted yeast cells with CO _2, generally, loaded into an extraction vessel filled with a plug of glass wool, flushed with CO _2, and then heated to the desired operating conditions in CO ₂ flow down and Pressurized. CO ₂ was fed directly from a commercial cylinder equipped with a discharge pipe and metered by a high pressure pump. The pressure is maintained on the extraction vessel through the use of a restrictor on the outlet side of the vessel, and the oil sample is collected in the sample vessel while simultaneously venting the CO ₂ solvent to the atmosphere. A co-solvent (eg, ethanol) can optionally be added to the extraction solvent fed to the extraction vessel via the use of a co-solvent pump (Isco model 100D syringe pump).

Unless otherwise stated, supercritical CO ₂ extraction of yeast samples in the following examples was performed in a custom-made high pressure extraction apparatus (FIG. 1). In general, dried and mechanically disrupted yeast cells (free flowing or pelleted) are loaded into an extraction vessel (1) filled with glass wool plugs, flushed with CO ₂ and then CO 2. It was heat and pressure to the desired operating conditions in ₂ flow. The 89 ml extraction vessel was fabricated from a 316SS tube (2.54 cm od × 1.93 cm id × 30.5 cm length) with a 2 micron sintered metal filter on the outflow end of the vessel. It was. The extraction vessel was placed inside a custom-machined aluminum block with four calrod heating cartridges controlled by an automated temperature controller. CO ₂ was directly fed as a liquid from a commercially available cylinder (2) equipped with a discharge tube and metered by a high pressure positive displacement pump (3) equipped with a refrigeration head assembly (Jasco model PU-1580-CO2). The extraction pressure is maintained by an automatic back pressure regulator (4) (Jasco model BP-1580-81) that provides flow restriction on the outflow side of the vessel, while the extracted oil sample is collected in the sample vessel while simultaneously collecting CO _Two solvents were vented to the atmosphere.

  The oil extraction yield from the reported yeast sample was weighed by measuring the mass loss from the sample during extraction. Thus, the reported extracted oil contains the moisture associated with microbial oil and solid pellets.

Examples Comparative Examples C1, C2A, C2B, Examples 1, 2 and Comparative Examples C3 and C4: Comparison of Means for Creating a Crushed Biomass Mixture from Drum Dry Flakes of Yarrowia lipolytica Comparative Examples C1, C2A, C2B, C3 and C4 and Examples 1 and 2 are a series of comparative tests conducted to optimize the disruption of drum dry flakes of yeast (ie, Yarrowia lipolytica strain Y8672) Is described. Specifically, a hammer mill process with or without the addition of a grinding agent was tested and either a single screw or twin screw extruder was used. Results are compared based on total free microbial oil and microbial cell disruption efficiency, and total extraction yield (based on supercritical CO ₂ extraction).

Comparative Example C1:
Hammer milled yeast powder without milling agent Drum-dried flakes of yeast (Y. lipolytica strain Y8672) biomass containing 24.2% total oil (dry weight) at a jump gap ( A jump gap) sorter at 16000 rpm was hammer milled (Mikropul Bantam mill at a feed rate of 12 Kg / h) with 3 hammers to provide milled powder. The particle size of the milled powder was d10 = 3 μm; d50 = 16 μm and d90 = 108 μm analyzed by suspending in water using Fraunhofer laser diffraction.

Comparative Example C2A:
Hammer-milled yeast powder using grinding agent and air mill mixing Hammer-milled yeast powder (833 g) provided by Comparative Example C1 was fed into an air (jet) mill (Fluid Energy Jet-o-mizer 0101, 6 Kg / h). Speed) and mixed with Celite 209 diatomaceous earth (167 g) at ambient temperature for about 20 minutes.

Comparative Example C2B:
Hammer-milled yeast powder with grinding agent and manual mixing Hammer-milled yeast powder provided by Comparative Example C1 (833 g) was manually mixed with Celite 209 diatomaceous earth (167 g) in a plastic bag.

Example 1:
Hammer milled yeast powder using grinding agent, manual mixing, and single screw extruder Hammer milled yeast powder (1000 g) with diatomaceous earth from Comparative Example C2B was added to a 17.6 wt% aqueous sucrose solution (291.6 g 62.5 g sucrose in water) in a Hobart mixer for about 2.5 minutes, then extruded through a single screw dome crusher with 1 mm opening (50-200 psi, not exceeding 550 in-lbs) Torque; extrudate temperature below 40 ° C). The extrudate was dried in a fluid bed dryer using fluid air controlled at 65 ° C. to a bed temperature of 50 ° C., and after about 14 minutes non-sticky pellets (815 g) with 3.9% residual water. Having a length of 2 to 8 mm and dimensions of about 1 mm diameter).

Example 2:
Hammer Mill Yeast Treated Powder Using Grinding Agent, Air Mill Mixing, and Single Screw Extruder Hammer mill yeast powder (1000 g) with diatomaceous earth from Comparative Example C2A was processed according to Example 1 and after about 10 minutes, 6. A pellet with 9% residual water (855 g, having a length of 2 to 8 mm and a diameter of about 1 mm diameter) was provided.

Comparative Example C3:
Hammer milled yeast powder using a twin screw extruder without grinding agent The hammer milled yeast powder provided from Comparative Example C1 was applied at 150 rpm and 66-68% torque range with a 10 kW motor and high torque shaft. Crushed yeast powder was fed to a working 18 mm twin screw extruder (Coperion Werner Pfleiderer ZSK-18 mm MC, Stuttgart, Germany) at 2.3 kg / hr and cooled to 26 ° C. in the final water-cooled barrel.

Comparative Example C4:
Yeast powder without grinding agent and using a twin screw extruder. Drum-dried flakes of yeast (Y. lipolytica Y8672) biomass containing 24.2% total oil, with a 10 kW motor and high Feeded at 2.3 kg / hr to 18 mm twin screw extruder (Coperion Werner Pfleiderer ZSK-18 mm MC) operating at 150 rpm and 71-73% torque range by torque shaft and cooled to 23 ° C. in the final water cooled barrel Crushed yeast powder was provided.

Comparison of free microbial oil and crushing efficiency in crushed yeast powder Free microbial oil and crushing efficiency were measured in the crushed yeast powders of Examples 1 and 2 and Comparative Examples C1 to C4 according to the following method. Specifically, the free oil and total oil content of extruded biomass samples were determined using a modified version of the method reported by Troeng (J. Amer. Oil Chemists Soc., 32: 124-126 (1955)). It was measured. In this method, a sample of extruded biomass was weighed into a stainless steel centrifuge tube having a measured volume of hexane. When total oil was to be measured, some chrome steel ball bearings were added. When free oil was to be measured, ball bearings were not used. The tube was then capped and charged on a shaker for 2 hours. The shaken sample was centrifuged, the supernatant was collected, and the volume was measured. Hexane was evaporated from the supernatant, first by rotating film evaporation, and then by evaporation under a stream of dry nitrogen until a constant weight was obtained. This weight was then used to calculate the percentage of free or total oil in the original sample. The oil content is expressed on a percent dry weight basis by measuring the moisture content of the sample and corrected accordingly.

  The percent disruption efficiency (ie, the percent of cell walls that broke during processing) was quantified by optical visualization.

  Table 7 summarizes the yeast cell disruption efficiency data for Examples 1 and 2 and Comparative Examples C1-C4 and represents the following:

  Comparative Example C1 shows that hammer mill treatment in the absence of grinding agent results in 33% disruption of the yeast cells.

  Comparative Example C2A shows that air jet milling of hammer milled yeast in the presence of a grinding agent increases yeast cell disruption to 62%.

  Example 1 shows that further mixing of hammer milled yeast (from Comparative Example C1) in a Hobart single screw mixer in the presence of a grinding agent increases yeast cell disruption to 38%. Show.

  Example 2 shows that further mixing of air milled and hammer milled yeast with a grinding agent (from Comparative Example C2A) in a Hobart single screw mixer increases yeast cell disruption to 57%. Indicates.

  Comparative Examples C3 and C4 had greater than 80% yeast cell disruption when using twin screw extrusion with a compression zone, with or without hammer milling (respectively) in the absence of grinding agent It shows that.

SCF extraction Approximately 25 g (yeast basis) of crushed yeast biomass of Comparative Examples C1, C2A and C4 were each loaded into an extraction vessel. The yeast was flushed with CO ₂ and then heated to about 40 ° C. and pressurized to about 311 bar. The yeast was extracted for about 6.7 hr at a CO ₂ flow rate of 4.3 g / min under these conditions, resulting in a final solvent feed (S / F) ratio of about 75 g CO ₂ / g yeast. The extraction yield is reported in the table below.

  The data show that higher cell disruption results in significantly higher extraction yields measured as weight percent of crude extracted oil.

Comparative examples C5A, C5B, C5C, C6A, C6B and C6C:
Comparison of means for creating a crushed biomass mixture from Yarrowia lipolytica Comparative Examples C5A, C5B, C5C, C6A, C6B and C6C are a series of comparative tests conducted to prepare crushed yeast powder. The first microbial biomass described was a drum-dried flake or spray-dried powder of yeast that was mixed or not mixed with the grinding agent in a twin screw extruder.

  In each of Comparative Examples C5A, C5B, C5C, C6A, C6B, and C6C, the initial yeast biomass has a moisture level of 2.8% and contains approximately 36% total oil (Yarlowia lipolytica). Y9502 strain. Dry yeast flakes or powders (with or without grinding agent) were fed into an 18 mm twin screw extruder (Coperion Werner Pfleiderer ZSK-18 mm MC) operating at 150 rpm with a 10 kW motor and high torque shaft. The resulting crushed yeast powder was cooled in the final water-cooled barrel.

Subsequently, the crushed yeast powder prepared in Comparative Examples C5A, C5B, C5C, C6A, C6B and C6C was subjected to supercritical CO ₂ extraction, and the total extraction yield was compared.

Comparative Example C5A:
Drum-dried yeast flakes without milling agent Drum-dried flakes of yeast biomass were fed at 2.3 kg / hr to a twin screw extruder operating with a% torque range of 34-35. The crushed yeast powder was cooled to 27 ° C.

Comparative Example C5B:
Drum-dried yeast flakes using milling agent Drum-dried flakes of 92.5 parts yeast biomass were premixed in a bag with 7.5 parts Celite 209 diatomaceous earth. The resulting dry mixture was fed at 2.3 kg / hr to a twin screw extruder operating with a% torque range of 44-47. The crushed yeast powder was cooled to 29 ° C.

Comparative Example C5C:
Drum-dried yeast flakes with milling agent Drum-dried flakes of 85 parts yeast biomass were premixed with 15 parts Celite 209 diatomaceous earth in a bag. The resulting dry mixture was fed at 2.3 kg / hr to a twin screw extruder operating with a% torque range of 48-51. The crushed yeast powder was cooled to 29 ° C.

Comparative Example C6A:
Spray-dried yeast powder without pulverizer Yeast biomass spray-dried powder was fed at 1.8 kg / hr to a twin screw extruder operating with a% torque range of 33-34. The crushed yeast powder was cooled to 26 ° C.

Comparative Example C6B:
Spray-dried yeast powder using grinding agent 92.5 parts of yeast biomass spray-dried powder was premixed in a bag with 7.5 parts of Celite 209 diatomaceous earth. The resulting dry mixture was fed at 1.8 kg / hr to a twin screw extruder operating with a% torque range of 37-38. The crushed yeast powder was cooled to 26 ° C.

Comparative Example C6C:
Spray-dried yeast powder with milling agent 85 parts of yeast biomass spray-dried powder was premixed in a bag with 15 parts of diatomaceous earth (Celite 209). The resulting dry mixture was fed at 1.8 kg / hr to a twin screw extruder operating with a% torque range of 38-39. The crushed yeast powder was cooled to 27 ° C.

SCF Extraction An extraction vessel was loaded with 11.7 g (yeast basis) of crushed yeast biomass of Comparative Examples C5A, C5B, C5C, C6A, C6B and C6C, respectively. The yeast was flushed with CO ₂ and then heated to about 40 ° C. and pressurized to about 311 bar. Yeast samples were extracted at these conditions for about 3.2 hr at a CO ₂ flow rate of 4.3 g / min, resulting in a final solvent feed (S / F) ratio of about 75 g CO ₂ / g yeast. The extraction yields for various formulations are reported in Table 9.

  The data show that samples with diatomaceous earth as a grinding agent (ie, Comparative Examples C5B, C5C, C6B and C6C) yield higher extraction yields when no diatomaceous earth is present (ie, Comparative Examples C5A and C6A). Show.

Examples 3, 4, 5, 6, 7, 8, 9 and 10
Comparison of means for making solid pellets from Yarrowia lipolytica Examples 3-10 were prepared by mixing yeast biomass spray-dried powder or drum-dried flakes with milling agent and binder to produce crushed microbial biomass. A series of comparative tests performed to provide solid pellets containing are described.

In each of Examples 3-10, the initial yeast biomass was from the Yarrowia lipolytica strain Y9502 having a moisture level of 2.8% and containing about 36% total oil. . After preparation of solid pellets of about 1 mm diameter × 2-8 mm length, the pellets were subjected to supercritical CO ₂ extraction and the total extraction yield was compared. The mechanical compression properties and wear resistance of the solid pellets were also analyzed.

Example 3:
85 parts of yeast biomass spray-dried powder was premixed with 15 parts of Celato MN-4 diatomaceous earth in a bag. The resulting dry mixture was fed to an 18 mm twin screw extruder (Coperion Werner Pfleiderer ZSK-18 mm MC) at 2.3 kg / hr. Along with the dry feed, a water / sugar solution made from 14 parts water and 5.1 parts sugar was injected at a flow rate of 8.2 ml / min after the crush zone of the extruder. The extruder provided a crushed yeast powder that was cooled to 24 ° C. in a final water-cooled barrel operating at 150 rpm and a 58-60% torque range with a 10 kW motor and high torque shaft.

  The fixable mixture was then assembled into a MG-55 LCI dome crusher assembled with a 1 mm hole diameter x 1 mm thick screen and set at 70 RPM. Extrudates were formed at 67.5 kg / hr and a steady 2.7 amp current. The sample was dried in a Sherwood dryer for 10 minutes to provide a solid pellet with a final moisture level of 7.1%.

Example 4:
The fixable mixture prepared according to Example 3 was passed through a grinder at 45 RPM. Extrudates were formed at 31.7 kg / hr and dried in a Sherwood dryer for 10 minutes to provide solid pellets with a final moisture level of 8.15%.

Example 5:
The fixable mixture prepared according to Example 3 was passed through a grinder at 90 RPM. The extruded pellets were dried in an MDB-400 fluid bed dryer for 15 minutes to provide solid pellets having a final moisture level of 4.53%.

Example 6:
85 parts of yeast biomass spray-dried powder was premixed with 15 parts of Celato MN-4 diatomaceous earth in a bag. The resulting dry mixture was fed at 2.3 kg / hr by a 10 kW motor and a high torque shaft to an 18 mm twin screw extruder (Coperion Werner Pfleiderer ZSK-18 mm MC) operating at 150 rpm and 70% to 74% torque range. To provide crushed yeast powder cooled to 31 ° C. in the final water-cooled barrel.

  The crushed yeast powder was then mixed with a 22.6% solution of sucrose and water (ie 17.5 parts water and 5.1 parts sugar) in a Kitchen Aid mixer. The total mixing time was 4.5 minutes and the solution was added over the first 2 minutes.

  The fixable mixture was assembled with a 1 mm hole diameter x 1 mm thick screen and fed to an MG-55LCI dome crusher set at 70 RPM. Extrudates were formed at 71.4 kg / hr and a steady 2.7 amp current. The sample was dried in a Sherwood dryer for a total of 20 minutes to provide a solid pellet with a final moisture level of 6.5%.

Example 7:
The crushed yeast powder prepared according to Example 6 was placed in a KDHJ-20 batch sigma blade kneader with a 22.6% solution of sucrose and water (ie 17.5 parts water and 5.1 parts sugar). I was charged. The total mixing time was 3.5 minutes and the solution was added over the first 2 minutes.

  The fixable mixture was assembled with a 1 mm hole diameter x 1 mm thick screen and fed to an MG-55 LCI dome crusher set at 90 RPM. Extrudates were formed at 47.5 kg / hr and a steady 2.3 amp current. The sample was dried in a Sherwood dryer for a total of 15 minutes to provide a solid pellet with a final moisture level of 7.4%.

Example 8:
Drum dried flakes of yeast biomass are fed at 1.8 kg / hr to a 18 mm twin screw extruder (Coperion Werner Pfleiderer ZSK-18 mm MC) operating at 150 rpm and 38-40% torque range with a 10 kW motor and high torque shaft Thus, the crushed yeast powder cooled to 30 ° C. in the final water-cooled barrel was provided.

  Breaking yeast powder (69.5 parts) into 12.2% Celite 209 diatomaceous earth (12.2 parts) and a sucrose aqueous solution (18.3 parts) made from water to sugar ratio 3.3 and Kitchen Aid. Mix in a blender. The total mixing time was 4.5 minutes and the solution was added over the first 2 minutes.

  The fixable mixture was assembled with a 1 mm hole diameter x 1 mm thick screen and fed to an MG-55 LCI dome crusher set at 90 RPM. Extrudates were formed at 68.2 kg / hr and a steady 2.5 amp current. The sample was dried in a Sherwood dryer for a total of 15 minutes to provide a solid pellet with a final moisture level of 6.83%.

Example 9:
Drum dried flakes of yeast biomass (85 parts) were premixed in a bag with 15 parts Celite 209 diatomaceous earth. The resulting dry mixture was fed to an 18 mm twin screw extruder (Coperion Werner Pfleiderer ZSK-18 mm MC) at 2.3 kg / hr. Along with the dry feed, a water / sugar solution made from 14 parts water and 5.1 parts sugar was injected at a flow rate of 8.2 ml / min after the crush zone of the extruder. The extruder provided a crushed yeast powder that was operated at 150 rpm and 61-65% torque range with a 10 kW motor and high torque shaft and cooled to 25 ° C. in the final water-cooled barrel.

  The fixable mixture was then assembled into a MG-55 LCI dome crusher assembled with a 1 mm hole diameter x 1 mm thick screen and set at 90 RPM. Extrudates were formed at 81.4 kg / hr and a steady 2.5 amp current. The sample was dried in a Sherwood dryer for 15 minutes to provide a solid pellet with a final moisture level of 8.3%.

Example 10:
Drum-dried flakes of yeast biomass (85 parts) were premixed in 15 bags with 15 parts of Celato NM-4 diatomaceous earth. The resulting dry mixture was fed to an 18 mm twin screw extruder (Coperion Werner Pfleiderer ZSK-18 mm MC) at 4.6 kg / hr. Along with the dry feed, a water / sugar solution made from 14 parts water and 5.1 parts sugar was injected at a flow rate of 8.2 ml / min after the crush zone of the extruder. The extruder was run at 300 rpm and a% torque range of about 34 with a 10 kW motor and high torque shaft to provide crushed yeast powder.

  The fixable mixture was then assembled into a MG-55 LCI dome crusher assembled with a 1 mm hole diameter x 1 mm thick screen and set at 90 RPM. Extrudates were formed at 81.4 kg / hr and a steady 2.5 amp current. The sample was dried in a Sherwood dryer for 15 minutes to provide solid pellets.

The compression test and wear resistance of the solid pellets were performed as follows. The test apparatus and protocol described in ASTM standard D-6683 was used to evaluate the response of the solid pellets to external loads, such as those loaded by a gas pressure gradient. In this test, the volume of known mass is measured as a function of mechanically applied consolidation stress. The resulting semi-log graph is typically a straight line with a slope β that reflects the compression of the sample. A higher β value reflects greater compression. This compression can indicate particle breakage resulting in unwanted sequestration and gas flow restriction during processing.

  At the end of the ASTM test, the load was maintained on the pellet for an additional 2 hours to simulate an extended processing time. The creep measured after 2 hours is a further indication that the solid pellet is likely to deform. Low creep indicates less deformation.

  The test cell containing the sample was then inverted and the pellet sample was poured out. If necessary, the cell was gently tapped to release the contents. The ease of emptying the cell and the resulting texture of the pellet (ie loose or agglomerated) were recorded.

  The post-test texture is a qualitative observation of how difficult it is to empty the test cell used in the previous measurement. While the most desirable samples poured out immediately, some samples required an increase in the amount of taps and could become large lumps (ie less desirable).

  To measure the abrasion resistance, solid pellets (10 g) pre-compressed in the compression test ASTM test were then transferred to a 3 inch diameter 500 micron sieve. The sieve was manually tapped to remove any initial pieces of pellets smaller than 500 microns. The net weight of the residual pellet was recorded. Three cylindrical grinding media beads, each 0.50 inch diameter x 0.50 inch thick and each weighing 5.3 grams, were then added to the sieve. The sieve was loaded into an automatic sieve shaker (Gilson Model SS-3, “8” setting, automated tap “on”) and shaken for 2, 5 or 10 minutes. The grinding media beads impact the pellet many times from a random angle. After shaking, the pan under the sieve was weighed and worn, and the amount of material dropped through the sieve was measured. This test shall simulate the very coarse handling of pellets after the oil extraction process.

  The solid pellets from Examples 3-10 were each analyzed to determine their compression properties and wear resistance. The results are summarized in Table 10 below.

SCF Extraction Extraction containers were each loaded with solid pellets from Examples 3-9 (based on dry weight, listed in Table 11). The pellet was flushed with CO ₂ and then heated to about 40 ° C. and pressurized to about 311 bar. The pellet was extracted for about 6.8 hr at a CO ₂ flow rate of 4.3 g / min under these conditions to give a final solvent feed (S / F) ratio of about 150 g CO ₂ / g yeast. In some examples, the second run was performed for an additional 4.8 hours such that the total extraction time was 11.6 hours. The oil extraction yield and the specified parameters used for extraction are listed in Table 11.

Compression test and wear resistance of residual pellets (after extraction) After SCF extraction, the residual pellets from Examples 3-9 were each analyzed to determine their compression characteristics and wear resistance. The results are summarized in Table 12 below.

  Based on the above, the method described herein [i.e., (a) mixing a microbial biomass having a moisture level and containing oil-bearing microorganisms and at least one oil-absorbing grinder to provide a crushed biomass mixture. (B) providing at least one binder with the crushed biomass mixture to provide a fixable mixture capable of forming solid pellets; and (c) forming the solid pellets from the fixable mixture. It can be concluded that the method comprising can be successfully utilized to produce solid pellets containing crushed microbial biomass from Yarrowia lipolytica. Furthermore, this example demonstrates that solid Yarrowia lipolytica pellets can be extracted with a solvent (ie, SCF extraction) to provide an extract containing microbial oil.

Example 11
A. Methods for Measuring Lipid Distribution for Yeast Cell Biomass, Oil, and Residual Biomass Samples Yeast cell samples and residual biomass samples (ie, yeast cells after extraction with CO ₂ ) were obtained from Bligh & Dyer (Lipid Analysis, WW). Extraction using a modification of the method (based on the procedure outlined in Christie 2003), separation by thin layer chromatography (TLC) and direct esterification / transesterification using methanolic hydrogen chloride. Oil samples were dissolved in chloroform / methanol and then separated by TLC and directly esterified / esterified. The esterified / transesterified sample was analyzed by gas chromatography.

  Yeast cells and residual biomass samples were received as dry powders. Pre-determined portions of sample (100-200 mg or less depending on PUFA concentration) are weighed into a 13 × 100 mm glass test tube with a Teflon ™ cap, to which 3 mL volume of 2: 1 (volume: volume) methanol / volume Chloroform solution was added. Samples were vortexed well, gently agitated and incubated for 1 hour at room temperature with inversion. After 1 hour, 1 mL of chloroform and 1.8 mL of deionized water were added, the mixture was stirred and then centrifuged to separate the two layers formed. Using a Pasteur pipette, the lower layer was removed into a second tar-coated 13 mm glass vial and the aqueous upper layer was re-extracted with a second 1 mL portion of chloroform for 30 minutes. The two extracts were combined and considered the “first extract”. The solvent is removed with dry nitrogen using TurboVap ™ at 50 ° C. and the residual oil is resuspended in an appropriate amount of 6: 1 (volume: volume) chloroform / methanol to give a 100 mg / mL solution. Got.

The oil sample from above as resulting oil (for yeast cells and residual biomass samples) and CO ₂ extracts of yeast cells was analyzed by TLC. TLC was typically performed using a single tank, but a two tank procedure was also used when individual PLs were to be identified. In one tank TLC procedure, a 5 × 20 cm silica gel 60 plate (EMD # 5724-3 from VWR) was prepared by drawing a thin pencil line over 2 cm from the bottom of the plate. An appropriate amount of sample (approximately 60 μL) was completely spotted across the plate on top of the pencil line, leaving no space between the spots. The second plate was spotted with known standards and samples using 1-2 μm amounts. Plates were allowed to air dry for 5-10 minutes and developed using a hexane-diethyl ether acetic acid mixture (70: 30: 1 volume basis) equilibrated in a bath with a piece of blotting paper for at least 30 minutes before running the plate. .

After the plates were developed within the upper ¼ inch, they were dried in an N ₂ environment for 15 minutes. A second plate with standard and small sample spots was then developed in a bath that was saturated with iodine crystals and served as a reference for the preparation plate. Bands on the preparation plate are stained very lightly with iodine at the end of the band, and using a pencil, band according to the respective fraction (ie PL fraction, FFA fraction, TAG fraction and DAG fraction). Identified by grouping. The DAG band may show some separation of the 1,2-DAG, 1,3-DAG, and MAG bands, and typically this entire region was cut out as a DAG band. Bands were cut from the gel and transferred to 13 mm glass vials. The rest of the plate was developed in an iodine bath to confirm complete removal of the band of interest.

  To a glass vial containing each band, an appropriate amount of triglyceride internal standard in toluene was added. Depending on the visible concentration of each band, 100 μL of 0.1 to 5 mg / mL internal standard was usually used. A co-solvent (in this case toluene) was added along with the internal standard. If the internal standard was not used, additional cosolvent was added to complete the long chain lipid esterification / transesterification. Add 1 mL of 1% methanolic hydrogen chloride solution (prepared by slowly adding 5 mL of acetyl chloride to 50 mL of chilled dry methanol), cap the sample, mix gently, and add 1 at 80 ° C. in a heating block. I was charged for hours. After 1 hour, the sample was removed and allowed to cool. 1 mL of 1N sodium chloride solution and 400 μL of hexane were added, then the sample was vortexed for at least 12 seconds and centrifuged to separate the two layers. The upper layer was then carefully handled and removed so as not to be contaminated by any of the aqueous (lower) layers. The upper layer was placed in a GC vial fitted with an insert and capped.

  The sample was an Agilent model 6890 gas chromatograph (Agilent Technologies, Santa Clara, with a flame ionization detector (FID) and an Omegawax 320 column (30 m × 0.32 mm ID × 25 μm film thickness, manufactured by Supelco, Bellfonte, Pa.). CA). The helium carrier gas was held constant within a range of 1-3 mL / min with a 20: 1 or 30: 1 split ratio. The oven conditions were as follows: an initial temperature of 160 ° C. with an initial time of 0 minutes and an equilibration time of 0.5 minutes. The temperature ramp was 5 degrees / min to 200 ° C. for a final hold time of 0 minutes, then 10 degrees / min to 240 ° C. for a hold time of 4 minutes for a total of 16 minutes. The inlet was set at 260 ° C. The FID detector was also set at 260 ° C. Nu-Chek Prep GLC reference standard (# 461) was run for residence time confirmation.

  GC results were collected using Agilent's Custom Reports, and the area of each fatty acid was transferred to an Excel spreadsheet for calculation of their proportions. A correction factor could then be applied to convert the total amount of fatty acids in the lipid class. The total proportion of each component was compared to the original extract derivatized before TLC.

B. Extraction method The extraction was carried out according to a general method. The analysis of the various lipid components in yeast and extract oils reported in Examples 12-20 below was determined using the thin layer and gas chromatography methods described herein above. For yeast samples, this summary reflects the analysis of lipids extracted from the samples using analytical procedures. The amount of lipid analyzed by this procedure for the extracted yeast sample is relatively small compared to the amount of comparable feed yeast and oil extract samples (typically <> of the extractable oil in the starting feed yeast. 3%). The results summary table shows the relative distribution of lipid components for each of the samples. For each identified lipid component shown in a row across the top of the table, phospholipid (PL), diacylglyceride (DAG), free fatty acid (FFA), and its component as triacylglyceride (TAG) The relative distribution is shown below the table column. The first line for each sample shows an analysis of the original extract derivatized before TLC. The following line lists the analysis of each component by TLC and GC, and the total percentage of each component is represented by the last line for that sample.

In Examples 12-20 below, the reported oil extraction yields were measured by the weight difference between the yeast sample before extraction and the residual biomass after extraction and expressed as a percentage. Weight difference was assumed to be due to the amount of oil extracted by contacting with CO _2. The actual weight of the resulting oil was generally found to be within about 85% of the expected weight based on mass difference.

Example 12
Extraction curve at 311 bar and 40 ° C. The purpose of this example was to demonstrate the creation of an extraction curve. Nominally 2.7 g of dried and mechanically crushed into 8 mL extraction vessel made from 316SS tube (0.95 cm od × 0.62 cm id × 26.7 cm length) Yeast cells (ie, Yarrowia lipolytica strain Y8672) were repeatedly loaded for a series of extractions to determine the extraction curve for this yeast sample at 40 ° C. and 311 bar. For each extraction, the extraction vessel and yeast flushed with CO _2, then pressurized to 311bar at 40 ° C. by CO _2. As shown in Table 13, yeast samples were extracted at 1.5 g / min CO ₂ flow rates over these conditions and various times to obtain a series of solvent feed ratios that yielded the corresponding extraction yields. FIG. 4 plots these data with an extraction curve. An interruption in the curve in the solvent feed ratio of about 40 g CO ₂ / g yeast requires at least this solvent ratio to efficiently extract the available oil in this particular yeast sample at the selected temperature and pressure. Indicates that

The series of extractions can be repeated at different temperature and / or pressure conditions to create a series of extraction curves for a particular microbial biomass sample, which can be, for example, economic, desired extraction yield, or CO used _The optimum extraction condition based on the total amount of ₂ can be selected.

Comparative Example C7
Extraction of yeast cells without fractionation of the resulting extract The purpose of this comparative example was to extract microbial biomass with CO ₂ without using fractionation of the extract or continuous extraction of residual biomass, and thus obtained It was to demonstrate the lipid composition of the extract. 4.99 g of dried and mechanically crushed into 18 mL extraction vessel made from 316SS tube (1.27 cm od × 0.94 cm id × 26.0 cm length) Yeast cells (i.e., Yarrowia lipolytica strain Y8672) were loaded. The yeast sample was flushed with CO ₂ then heated to 40 ° C. and pressurized to 222 bar. Yeast samples were extracted for 5.5 hours at a CO ₂ flow rate of 2.3 g / min under these conditions to give a final solvent feed ratio of 149 g CO ₂ / g yeast. The yield of the extract was 18.2% by weight.

The following table summarizes the lipid analysis for the starting feed yeast (microbial biomass), extracted yeast (residual biomass), and the resulting extract. For yeast cells, 50 weight percent (wt%) of FFA and 59.8 wt% of TAG is a 3/6 ratio [wt% of FFA including EPA in feed yeast is the total wt% of FFA in feed yeast. Divided by, expressed as a percentage, both percentage values were taken from the TLC analysis] and a 49/82 percentage [wt% of TAG with EPA in feed yeast is divided by total weight of TAG in feed yeast] It was found to contain EPA each expressed as divided, expressed as a percentage, both percentage values taken from TLC analysis. Absence of PL in the extract (0 wt%) indicates that the PL fraction of lipids present in the starting feed yeast remaining residual biomass, not sectioned in the extract by CO _2. The results also show that the extract contains 90 wt% TAG, 4 wt% FFA, and 6 wt% DAG. For the extract, 50% FFA and 58.9% TAG were in a ratio of 2/4 [weight percent of FFA with EPA in extract divided by total weight percent of FFA in extract, proportion Both percentage values were taken from the TLC analysis] and a ratio of 53/90 (% by weight of TAG with EPA in the extract divided by the total weight% of TAG in the extract, as a percentage Expressed and both percentage values were found to contain EPA each calculated as TLC analysis).

Example 13
Lipid fractionation by continuous pressure extraction The purpose of this example was to demonstrate the continuous pressure extraction of a yeast sample and the lipid composition of the resulting extract. 3.50 g dried and mechanically crushed yeast into an 18 mL extraction vessel made from 316SS tube (1.27 cm od × 0.94 cm id × 26.0 cm length) Cells were loaded (ie, Yarrowia lipolytica strain Y8672).

Extract A: Yeast was flushed with CO ₂ and then heated to 40 ° C. and pressurized to 125 bar. Yeast samples were extracted at these conditions for 5 hours at a flow rate of 2.3 g / min CO ₂ , during which time the pressure was increased to 150 bar. The extraction was continued for an additional 1.2 hours to obtain a final solvent feed ratio of 238 g CO ₂ / g yeast. The yield of Extract A was 11.7% by weight.

Extract B: Extraction is continued by increasing the pressure to 222 bar using the same partially extracted yeast sample and continuing the CO ₂ flow for 4.0 hours at 2.3 g / min, and for this fraction 153 g A final solvent feed ratio of CO ₂ / g yeast was obtained. The yield of extract B was 6.2% by weight of the original yeast loaded in the extraction vessel.

The following table summarizes the lipid analysis for the starting feed yeast and the two extracts. The results show that, under the extraction conditions used, the microbial biomass oils FFA and DAG were selectively partitioned into Extract A (containing 9% by weight each), while Extract B was enriched with TAG. (Only 1% by weight of DAG was contained, and FFA was not measured). More specifically, Extract B is about 99% TAG, and about 62.6% of TAG has a ratio of 62/99 [weight% of TAG containing EPA in Extract B. Divided by the total weight percent of TAG in, expressed as a percentage, both percentage values taken from TLC analysis] were found to contain EPA). In contrast, about 59.8% of the TAG in the yeast cell was 49/82 ratio (weight% of TAG containing EPA in feed yeast divided by total weight% of TAG in feed yeast, as a percentage Expressed and both percentage values were found to contain EPA calculated as taken from TLC analysis). These results are expected to be similar to the results that can be obtained by SCFCO ₂ extraction of yeast samples to provide extracts that are subsequently fractionated via stepwise vacuum.

Example 14
Lipid fractionation by continuous pressure extraction The purpose of this example was to demonstrate the continuous pressure extraction of yeast samples under different extraction conditions and the lipid composition of the resulting extract. 15.0 g of dried and mechanically crushed yeast in 89 mL extraction vessel made from 316SS tube (2.54 cm od × 1.93 cm id × 30.5 cm length) Cells were loaded (ie, Yarrowia lipolytica strain Y8672).

Extract A: Yeast was flushed with CO ₂ and then heated to 40 ° C. and pressurized to 125 bar. The yeast sample is extracted at these conditions for 3.9 hours at a CO ₂ flow rate of 2.3 g / min, at which time the flow rate is increased to 4.7 g / min CO ₂ and extraction continues for an additional 2.3 hours. did. The pressure was then increased to 141 bar. The extraction was continued for an additional 4.1 hours at 4.7 g / min CO ₂ to give a final solvent feed ratio of 154 g CO ₂ / g yeast. The yield of Extract A was 8.7% by weight.

Extract B: Extraction is continued by increasing the pressure to 222 bar using the same partially extracted yeast sample and continuing the CO ₂ flow at 4.7 g / min for 8.0 hours, and for this extract 150 g A final solvent feed ratio of CO ₂ / g yeast was obtained. The yield of Extract B was 15.4% by weight of the original yeast loaded in the extraction vessel.

The table below summarizes the lipid analysis for the starting feed yeast, residual biomass after both extractions and the two extracts. The results show that the PL fraction of lipid present in the starting feed yeast remains in the residual biomass. Under the extraction conditions used, the microbial biomass FFA and DAG were selectively partitioned into Extract A, while Extract B was enriched with TAG. More specifically, Extract B was about 97% TAG, FFA was not measured, and about 61.9% of TAG was found to contain EPA. In contrast, it was found that about 59.8% of TAGs in yeast cells contain EPA. These results are expected to be similar to the results that can be obtained by SCFCO ₂ extraction of yeast samples to provide extracts that are subsequently fractionated via stepwise vacuum.

Example 15
Lipid fractionation by continuous pressure extraction The purpose of this example was to demonstrate the continuous pressure extraction of yeast samples under different extraction conditions and the lipid composition of the resulting extract. In an 89 mL extraction vessel made from a 316SS tube (2.54 cm od × 1.93 cm id × 30.5 cm length), 20.0
g dry and mechanically disrupted yeast cells (ie, Yarrowia lipolytica strain Y8672) were loaded.

Extract A: Yeast was flushed with CO ₂ and then heated to 40 ° C. and pressurized to 110 bar. Yeast samples were extracted for 7.1 hours at a flow rate of 4.7 g / min CO ₂ under these conditions to give a final solvent feed ratio of 100 g CO ₂ / g yeast. The yield of Extract A was 4.1% by weight.

Extract B: Extraction is continued by increasing the pressure to 222 bar using the same partially extracted yeast sample and continuing the CO ₂ flow at 4.7 g / min for 15.0 hours, with 212 g for this extract. A final solvent feed ratio of CO ₂ / g yeast was obtained. The yield of Extract B was 14.6% by weight of the original yeast loaded in the extraction vessel.

The table below summarizes the lipid analysis for the starting feed yeast, residual biomass after both extractions and the two extracts. The results show that the PL fraction of lipid present in the starting feed yeast remains in the residual biomass. Under the extraction conditions used, the microbial biomass FFA and DAG were selectively partitioned into Extract A, while Extract B was enriched with TAG (ie, Oil Fraction B was about 95% TAG). there were). These results are expected to be similar to the results that can be obtained by SCFCO ₂ extraction of yeast samples to provide extracts that are subsequently fractionated via stepwise vacuum.

  Examples 13 to 15 herein collectively illustrate that the partitioning of lipid constituents of an extract can be influenced by the selection of extraction conditions in a multi-stage extraction. Such segmentation is probably obtained from a continuous reduction in the pressure of the oil extract obtained by the process illustrated in FIG.

Example 16
SCF extraction The purpose of this example in 500 bar was to demonstrate the composition of extract of yeast cells, and the resulting extract by CO ₂ as the supercritical fluid in the 500 bar. Such an extraction condition is a method of obtaining a refined composition comprising at least one PUFA, wherein the microbial biomass comprising at least one PUFA is contacted with CO ₂ under suitable extraction conditions, followed by the extraction of the extract. For example, it could be used in the first step of the process involving fractionation by continuous vacuum.

A 10 mL extraction vessel is loaded with 2.01 g of dried and mechanically disrupted yeast cells (ie, Yarrowia lipolytica strain Y4305-F1B1) and the vessel is placed on a commercially available automated supercritical fluid extraction device, In an Isco model SFX3560 extractor. This apparatus utilized a 10 mL plastic extraction vessel with a 2 micron sintered metal filter on each end of the extraction vessel. The vessel was loaded with the substrate to be extracted and then loaded into a high pressure extraction chamber that equalized the pressure on the inside and outside of the extraction vessel. CO ₂ solvent was metered in with a syringe pump (ISCO model 260D), preheated to the specified extraction temperature, and then passed through the extraction vessel. The extraction chamber was heated to the desired extraction temperature with an electric resistance heater. The pressure was maintained on the vessel by an automated variable restrictor that was an integral part of the device.

The yeast sample was flushed with CO ₂ and then heated to 40 ° C. and pressurized to 500 bar. Yeast samples were extracted 5.8 hours at a flow rate of CO ₂ 0.86 g / min at these conditions, to give a final solvent feed ratio of 150 g _CO 2 / g yeast. The yield of extracted oil was 32.8% by weight. The following table summarizes the lipid analysis for the starting feed yeast, the residual biomass after extraction and the oil obtained by extraction. The results show that the PL fraction of lipids present in the starting feed yeast remained in the residual biomass and was not partitioned into CO ₂ extract oils containing FFA, DAG, and TAG.

Example 17
SCF extraction The purpose of this example in 310Bar was to demonstrate the composition of extract of yeast cells, and the resulting extract by CO ₂ as the supercritical fluid in 310Bar. Such an extraction condition is a method of obtaining a refined composition comprising at least one PUFA, wherein the microbial biomass comprising at least one PUFA is contacted with CO ₂ under suitable extraction conditions, followed by the extraction of the extract. For example, it could be used in the first step of the process involving fractionation by continuous vacuum.

25.1 g of dried and mechanically crushed into 89 mL extraction vessel made from 316SS tube (2.54 cm od × 1.93 cm id × 30.5 cm length) Yeast cells (ie, Yarrowia lipolytica strain Y9502) were loaded. The yeast sample was flushed with CO ₂ and then heated to 40 ° C. and pressurized to 310 bar. Yeast samples were extracted 4.4 hours at a flow rate of 5.0 mL / Minco ₂ In these conditions, to give a final solvent feed ratio of _CO 2 / g yeast 50 g. The yield of extracted oil was 28.8% by weight. The following table summarizes the lipid analysis for the starting feed yeast, the residual biomass after extraction and the oil obtained by extraction. The results show that the PL fraction of lipids present in the starting feed yeast remained in the residual biomass and was not partitioned into CO ₂ extract oils containing FFA, DAG, and TAG.

Example 18
SCF extraction The purpose of this example in 222Bar was to demonstrate the composition of extract of yeast cells, and the resulting extract by CO ₂ as the supercritical fluid in 222Bar. Such an extraction condition is a method of obtaining a refined composition comprising at least one PUFA, wherein the microbial biomass comprising at least one PUFA is contacted with CO ₂ under suitable extraction conditions, followed by the extraction of the extract. For example, it could be used in the first step of the process involving fractionation by continuous vacuum.

25.1 g of dried and mechanically crushed into 89 mL extraction vessel made from 316SS tube (2.54 cm od × 1.93 cm id × 30.5 cm length) Yeast cells (i.e., Yarrowia lipolytica strain Y8672) were loaded. The yeast sample was flushed with CO ₂ then heated to 40 ° C. and pressurized to 222 bar. Yeast samples were extracted 13.7 hours at a flow rate of 4.7 g / Minco ₂ In these conditions, to give a final solvent feed ratio of _CO 2 / g yeast 154 g. The yield of extracted oil was 18.1% by weight. This extraction was repeated a further 4 times, and 5 extracts were established using a new yeast sample at each time. Residual biomass samples and extracted oil samples were also established and mixed to provide composite samples from five extractions. The following table summarizes the lipid analysis for the starting feed yeast, the established residual biomass and the established oil obtained by extraction. The oil was found to contain 7 wt% FFA, 7 wt% DAG, and 86 wt% TAG.

Example 19
Liquid CO ₂ extraction at 85 bar The purpose of this example was to demonstrate the extraction of yeast cells with CO ₂ as liquid at 85 bar and the composition of the resulting extract. Such an extraction condition is a method of obtaining a refined composition comprising at least one PUFA, wherein the microbial biomass comprising at least one PUFA is contacted with CO ₂ under suitable extraction conditions, followed by the extraction of the extract. For example, it could be used in the first step of the process involving fractionation by continuous vacuum.

0.966 g of dried and mechanically crushed into 8 mL extraction vessel made from 316SS tube (0.95 cm od × 0.62 cm id × 26.7 cm length) Yeast cells (i.e., Yarrowia lipolytica strain Y8672) were loaded. The yeast sample was flushed with CO ₂ and then pressurized to 85 bar with liquid CO _{2 at} 22 ° C. Yeast samples were extracted for 8.5 hours at a flow rate of 0.69 g / min CO ₂ under these conditions to give a final solvent feed ratio of 361 g CO ₂ / g yeast. The yield of extracted oil was 21.4% by weight. The following table summarizes the lipid analysis for the starting feed yeast, residual biomass and oil obtained by extraction. The results show that PL fraction of lipids present in the starting feed yeast remaining residual biomass, were not partitioned into CO ₂ extracted oil. The oil contained 8 wt% FFA, 5 wt% DAG, and 86 wt% TAG.

Example 20
Extraction of residual phospholipids with SCFCO ₂ / EtOH The purpose of this example is to obtain a first residual biomass with a mixture of supercritical CO ₂ and ethanol as extractant to obtain a PL fraction and a second residual biomass sample It was to demonstrate sample extraction.

In an 18 mL extraction vessel made from a 316 SS tube (1.27 cm od × 0.94 cm id × 26.0 cm length), 6.39 g residual biomass from Example 13 ( Extracted Yarrowia lipolytica (Y8672 strain) is loaded and is referred to herein as the first residual biomass. The material was flushed with CO ₂ and then pressurized to 222 bar with a CO ₂ / methanol mixture (extractant) at 40 ° C. The CO ₂ flow rate was 2.3 g / min, the ethanol flow rate was 0.12 g / min, and an ethanol concentration of 5.0% by weight in the solvent fed to the extraction vessel was obtained. The first residual biomass was extracted for 5.3 hours at these conditions to give a final solvent feed ratio of 120 g CO ₂ / ethanol per gram of residual biomass. The oil extraction yield was 2.4% by weight from this pre-extracted material. The following table is obtained by extraction of the first residual biomass (starting sample for this example), the second residual biomass (first residual biomass after extraction in this example), and the first residual biomass. Summarize lipid analysis for the oils obtained. As can be seen from the data in the table below, the oil was found to contain essentially pure PL. The extraction performed in advance in Example 13 already removed triglycerides and free fatty acids from the yeast cells.

Example 21
The purpose of this example is to provide an alternative microbial biomass comprising at least one polyunsaturated fatty acid that can be utilized as a microbial biomass in the pelleting, extraction, fractionation and distillation methods described herein. is there.

  A number of oleaginous yeasts genetically engineered for the production of ω-3 / ω-6 PUFAs are preferred microbial biomass according to the invention described in this application, but representative strains of the oleaginous yeast Yarrowia lipolytica are It is described in Table 5. These include the following strains deposited by ATCC: Y. lipolytica strain Y2047 (producing ARA; ATCC accession number PTA-7186); Y. lipolytica strain Y2096 (Generate EPA; ATCC deposit number PTA-7184); Y. lipolytica Y2201 strain (generate EPA; ATCC deposit number PTA-7185); Y. lipolytica Y3000 strain (DHA) AT.CC deposit number PTA-7187); Y. lipolytica Y4128 strain (producing EPA; ATCC deposit number PTA-8614); Y. lipolytica strain Y4127 (EPA. Y. lipolytica Y8406 strain (producing EPA; ATCC deposit number PTA-10025); Y. lipolytica Y8412 strain (producing EPA; ATCC depositing; ATCC depositing; ATCC depositing) No. PTA-10026); and Y. lipolytica strain Y8259 (producing EPA; ATCC accession number PTA-10027).

  Thus, for example, Table 5 shows GLA from 25.9% to 34% of total fatty acids, 10.9% to 14% ARA of total fatty acids, 9% to 61.8% EPA of total fatty acids and total fatty acids. A microbial host producing 5.6% DHA is shown.

  One skilled in the art will not be limited to microbial biomass where the methodology of the present invention demonstrates high levels of EPA production, but instead demonstrates alternative omega-3 / ω-6 PUFAs or combinations thereof or high levels of PUFA production. Recognize that it is equally suitable for microbial biomass.

Example 22A
Preparation of untreated microbial biomass containing EPA from Yarrowia lipolytica strain Z1978 This example shows recombinant Yarrowia lipolytica strain Z1978 and a two-stage fed-batch process genetically engineered for EPA production. The means used to cultivate this strain using is described. The microbial biomass was pretreated to yield dry untreated microbial biomass with 56.1 EPA% TFA.

Generation of Yarrowia lipolytica Z1978 strain from Y9502 strain The development of the Z1978 strain from the strain has been described in US patent application Ser. No. 13 / 218,591 (EI DuPont), which is incorporated herein by reference. de Nemours & Co., Inc., attorney docket number CL4783 USNA, filed August 26, 2011).

  Specifically, the construct pZKUM (FIG. 6A; SEQ ID NO: 1; US Patent Application Publication No. 2009-0093543-A1) is described in Table 15 in order to disrupt the Ura3 gene of the Y9502 strain (see the above-mentioned material). ) Was used to integrate the Ura3 mutant gene into the Ura3 gene of strain Y9502. Transformation was performed according to the methodology of US Patent Application Publication No. 2009-0093543-A1, which is incorporated herein by reference. A total of 27 transformants (selected from a first group comprising 8 transformants, a second group comprising 8 transformants, and a third group comprising 11 transformants), 5-Fluororotic acid [“FOA”] plates (FOA plates contain the following per liter: 20 g glucose, 6.7 g yeast nitrogen basic medium, 75 mg uracil, 75 mg uridine and 100 mg / L to 1000 mg The appropriate amount of FOA (Zymo Research Corp., Orange, CA) based on the FOA activity test for a range of / L concentrations (because variations occur within each batch received from the supplier)) Grown on. Further experiments determined that only a third group of transformants had an actual Ura-phenotype.

  For fatty acid [“FA”] analysis, cells were collected by centrifugation and lipids were analyzed by Bligh, E .; G. & Dyer, W.M. J. et al. (Can. J. Biochem. Physiol., 37: 911-917 (1959)). Fatty acid methyl esters [“FAME”] were prepared by transesterification of lipid extracts with sodium methoxide (Roughhan, G., and Nishida I., Arch Biochem Biophys., 276 (1): 38-46 (1990). ), Followed by a Hewlett-Packard 6890 GC equipped with a 30-m × 0.25 mm (id) HP-INNOWAX (Hewlett-Packard) column. The oven temperature was 170 ° C. (held for 25 minutes) to 185 ° C. at 3.5 ° C./min.

  For direct base transesterification, Yarrowia cells (0.5 mL culture) were collected, washed once in distilled water, and dried in a Speed-Vac for 5-10 minutes under vacuum. Sodium methoxide (100 μl of 1%) and a known amount of C15: 0 triacylglycerol (C15: 0TAG; catalog number T-145, Nu-Check Prep, Elysian, MN) are added to the sample and then the sample is vortexed And locked at 50 ° C. for 30 minutes. After the addition of 3 drops of 1M NaCl and 400 μl hexane, the sample was vortexed and rotated. The upper layer was removed and analyzed by GC (supra).

  Alternatively, Lipid Analysis, William W. A modification of the base-catalyzed transesterification method described by Christie, 2003 was used for routine analysis of broth samples from fermentation or flask samples. Specifically, broth samples were thawed rapidly in room temperature water and then tar coated 2 mL with a 0.22 μm Corning® Costar® Spin-X® centrifugal tube filter (Catalog Number 8161). Weighed into a microcentrifuge tube (to 0.1 mg). Samples (75-800 μl) were used depending on the pre-measured DCW. Using an Eppendorf 5430 centrifuge, the sample was centrifuged at 14,000 rpm for 5-7 minutes or as needed to remove the broth. The filter was removed, the liquid was drained, and approximately 500 μl of deionized water was added to the filter to wash the sample. After removing water by centrifugation, the filter was removed again, the liquid was drained, and the filter was reinserted. The tube was then reinserted into the centrifuge, with the top open and allowed to dry for about 3-5 minutes. The filter was then cut at about one half of the tube and inserted into a new 2 mL round bottom Eppendorf tube (catalog number 2236335-2).

  The filter was pressed against the bottom of the tube with a suitable tool that only contacted the periphery of the cut filter container and not the sample or filter material. A known amount of C15: 0TAG (supra) in toluene was added, and 500 μl of a freshly made solution of 1% sodium methoxide in methanol. The sample pellet was completely disintegrated with a suitable tool, the tube was sealed and placed in a 50 ° C. heating block (VWR catalog number 12621-088) for 30 minutes. The tube was then allowed to cool for at least 5 minutes. Then 400 μl hexane and 500 μl 1M NaCl solution in water were added and the tube was vortexed twice for 6 seconds and centrifuged for 1 minute. About 150 μl of the top (organic) layer was placed in a GC vial with an insert and analyzed by GC.

The FAME peak recorded via GC analysis was identified by its residence time compared to a known fatty acid and quantified by comparing the FAME peak area with a known amount of internal standard (C15: 0TAG). Thus, the approximate amount (μg) [“μg FAME”] of any fatty acid FAME is calculated according to the formula: (FAME peak area for the specified fatty acid / standard FAME peak area) ^* (standard C15: 0 μg of 0TAG), while C15 : 1 μg of 0TAG is equal to 0.9503 μg fatty acid, so the amount of any fatty acid (μg) [“μg FA”] is the formula: (FAME peak area for a specific fatty acid / standard FAME peak area) ^* (Standard C15: 0 TAG μg) ^* Calculated according to 0.9503. Note that the 0.9503 conversion factor is an approximation of the value determined for most fatty acids ranging from 0.95 to 0.96.

  A lipid profile summing the amount of each individual fatty acid as a weight percent of TFA was determined by dividing the individual FAME peak area by the sum of all FAME peak areas and multiplying by 100.

  Thus, GC analysis was performed on the third group of pZKUM-transformants # 1, # 3, # 6, # 7, # 8, # 10 and # 11, respectively, 28.5%, 28.5%, 27 .4%, 28.6%, 29.2%, 30.3% and 29.6% EPA TFA were present. These seven strains were named Y9502U12, Y9502U14, Y9502U17, Y9502U18, Y9502U19, Y9502U21 and Y9502U22 strains (collectively Y9502U) strains, respectively.

  The construct pZKL3-9DP9N (FIG. 6B; SEQ ID NO: 2) was then generated to transfer one δ-9 desaturase gene, one choline phosphate cytidylyltransferase gene, and one δ-9 elongase mutant gene to strain Y9502U. Integrated into the Yarrowia YALI0F32131p locus (GenBank accession number XM — 506121). The pZKL3-9DP9N plasmid contained the following components:

The pZKL3-9DP9N plasmid was digested with AscI / SphI and then used for transformation of the Y9502U17 strain. Transformant cells were plated on minimal medium [“MM”] plates and maintained at 30 ° C. for 3-4 days (minimal medium: 20 g glucose, no 1.7 g amino acids) Yeast nitrogen basic medium, 1.0 g proline, and pH 6.1 (no adjustment needed)). Single colonies were streaked again on MM plates, then inoculated into liquid MM at 30 ° C. and shaken at 250 rpm / min for 2 days. Cells were harvested by centrifugation, resuspended in high glucose medium [“HGM”] and then shaken at 250 rpm / min for 5 days (high glucose medium: 80 g glucose per liter: 2.58 g Of KH ₂ PO ₄ and 5.36 g of K ₂ HPO ₄ , pH 7.5 (no adjustment required). Cells were subjected to the fatty acid analysis described above.

  GC analysis indicated that most of the Y9502U17 strains with 96 selected pZKL3-9DP9Ns produced 50-56% EPA TFA. Five strains that produced 59.0%, 56.6%, 58.9%, 56.5%, and 57.6% EPA TFA (ie, # 31, # 32, # 35, # 70 and # 80) were named Z1977, Z1978, Z1979, Z1980 and Z1981, respectively.

  The final genotypes of these pZKL3-9DP9N transformant strains for the wild type Yarrowia lipolytica ATCC # 20362 are Ura +, Pex3-, unknown1-, unknown6-, unknown5-, unknown-, unknown, , Unknown7-, unknown8-, unknown9-, unknown10-, unknown11-, YAT1 :: ME3S :: Pex16, GPD :: ME3S :: Pex20, YAT1 :: ME3S :: Lip1, FBAINm :: EgD9eS :: P1: : EgD9eS :: Lip1, GPAT :: EgD9e :: Lip2, YAT1 :: EgD9eS :: Lip2, Y T :: EgD9eS-L35G :: Pex20, FBAINm :: EgD8M :: Pex20, EXP1 :: EgD8M :: Pex16, FBAIN :: EgD8M :: Lip1, GPD :: EaD8S :: Pex16 (2 copies), YAT1 :: E389De / EgD8M :: Lip1, YAT1 :: EgD9eS / EgD8M :: Aco, FBAINm :: EaD9eS / EaD8S :: Lip2, GPIN :: YlD9 :: Lip1, GPD :: FmD12 :: Pex20, YAT1 :: FmD12: EXP1 :: FmD12S :: Aco, GPIN :: FmD12 :: Pex16, EXP1 :: EgD5M :: Pex16, FBAIN :: EgD5SM :: Pex20, GPIN :: EgD5SM :: Aco, GPM :: EgD5SM :: Oct, EXP1 :: EgD5SM :: Lip1, YAT1 :: EaD5SM :: Oct, FBAINm :: PaD17 :: Aco, EXP1 :: PaD17 :: Pex16, YAT1 :: PaD17S :: Lip1, YAT1: : YlCPT :: Aco, YAT1 :: MCS :: Lip1, FBA :: MCS :: Lip1, YAT1 :: MaLPAAT1S :: Pex16, EXP1 :: YlPCT :: Pex16.

  Knockout of the YALI0F32131p locus (GenBank accession number XM — 50612) of the Z1977, Z1978, Z1979, Z1980 and Z1981 strains was not confirmed in any of these EPA strains generated by transformation with pZKL3-9DP9N.

  Cells from YPD plates of Z1977, Z1978, Z1979, Z1980 and Z1981 strains were grown and analyzed for total lipid content and composition according to the following methodology.

Y. For a detailed analysis of the total lipid content and composition of a specific strain of Lipolytica (Y. lipolytica), a flask assay was performed as follows. Specifically, one loop of freshly streaked cells was inoculated into 3 mL of fermentation medium [“FM”] medium and grown overnight at 250 rpm and 30 ° C. (fermentation medium per liter : 6.70 g / L yeast nitrogen basic medium, 6.00 g KH ₂ PO ₄ , 2.00 g K ₂ HPO ₄ , 1.50 g MgSO ₄ ^* 7H ₂ O, 20 g glucose and 5.00 g Including yeast extract (BBL). OD _{600 nm} was measured and an aliquot of cells was added to a final OD ₆₀₀ nm of 0.3 with 25 mL FM medium in a 125 mL flask. After 2 days in a shaker incubator at 250 rpm and 30 ° C., 6 mL cultures were collected by centrifugation and resuspended in 25 mL HGM in a 125 mL flask. After 5 days in a shaker incubator at 250 rpm and 30 ° C., 1 mL aliquots were used for fatty acid analysis (supra) and 10 mL were dried for dry cell weight [“DCW”] measurements.

  For DCW measurements, 10 mL cultures were harvested by centrifugation at 4000 rpm for 5 minutes in a Beckman GH-3.8 rotor in a Beckman GS-6R centrifuge. The pellet was resuspended in 25 mL water and recollected as described above. The washed pellet was resuspended in 20 mL water and transferred to a pre-weighed aluminum pan. The cell suspension was dried in a vacuum oven at 80 ° C. overnight. The cell weight was measured.

  The total lipid content of the cells [“TFA% DCW”] is calculated, the concentration of each fatty acid as the weight percent of TFA [“% TFA”] and the EPA content as a percentage of the dry cell weight [“EPA% DCW]. ]] Together with data to summarize.

  Thus, Table 24 below summarizes the total lipid content and composition of strains Z1977, Z1978, Z1979, Z1980 and Z1981 as measured by flask assay. Specifically, this table shows the total dry cell weight of cells [“DCW”], the total lipid content of cells [“TFA% DCW”], the concentration of each fatty acid as a weight percent of TFA [“% TFA”. ]] And EPA content as a percentage of dry cell weight ["EPA% DCW"].

  Subsequently, the Z1978 strain was subjected to partial genome sequencing (US Patent Application No. 13/218591). This work determined that four (not six) δ-5-desaturase genes were integrated into the Yarrowia genome (ie, EXP1 :: EgD5M :: Pex16, FBAIN :: EgD5SM :: Pex20, EXP1 :: EgD5SM :: Lip1, and YAT1 :: EaD5SM :: Oct).

Fermentation of Yarrowia lipolytica strain Z1978 Yarrowia lipolytica strain Z1978 was grown in a two-stage fed-batch process as described in the material section above.

  After fermentation, the yeast biomass was dehydrated and washed to remove salt and residual media to minimize lipase activity. The drum was then dried to reduce moisture to less than 5% to ensure oil stability during short term storage and transportation.

Characterization of the biomass of dried untreated Yarrowia lipolytica strain Z1978 The fatty acid composition of the dried untreated yeast biomass was analyzed using the following gas chromatography [“GC”] method. Specifically, triglycerides were converted to fatty acid methyl esters [“FAME”] by transesterification using sodium methoxide in methanol. The resulting FAME was analyzed using an Agilent 7890 GC equipped with a 30-m × 0.25 mm (id) OMEGAWAX (Supelco) column after dilution in toluene / hexane (2: 3). The oven temperature was increased from 160 ° C. to 200 ° C. at 5 ° C./min and then from 200 ° C. to 250 ° C. (held for 10 minutes) at 10 ° C./min.

FAME peaks recorded via GC analysis are identified by their retention time compared to the known methyl ester [“ME”], and the FAME peak area is determined for a known amount of internal standard (C15: 0 triglyceride, for sample Quantification by comparison with (collected via transesterification procedure). Thus, the approximate amount (mg) [“mgFAME”] of any fatty acid FAME is calculated according to the formula: (FAME peak area for the specified fatty acid / 15: 0 FAME peak area) ^* (internal standard C15: 0 mg of FAME) . The FAME result can then be corrected to mg of the corresponding fatty acid by dividing by the appropriate molecular weight conversion factor of 1.042 to 1.052.

  The lipid profile summarizing the amount of each individual fatty acid as a weight percent of TFA is obtained by dividing the individual FAME peak area by the sum of all FAME peak areas and multiplying by 100 (within ± 0.1 wt%). Approximated.

  Dry untreated yeast biomass from Yarrowia lipolytica strain Z1978 contained 56.1 EPA% TFA as shown in the table below.

Example 22B
Preparation of SPD Refined Microbial Oil with Reduced Sterol Content from Untreated Yarrowia lipolytica Z1978 Strain Biomass This example represents the dried untreated Yarrowia lipolytica Z1978 strain biomass of Example 22A Crushing through extrusion and pelletization, extracting oil using supercritical fluid extraction [“SCFE”], and reducing the sterol content of the oil by distillation using short path distillation conditions Describes the means used to provide the minute (ie, SPD refined microbial oil).

Crushing and Pelletization via Extrusion of Dry Untreated Yeast Biomass The dry untreated Y. lipolytica Z1978 strain biomass of Example 22A was fed to a twin screw extruder. Specifically, a mixture of 84 weight percent yeast (containing about 39% total microbial oil) and 16% diatomaceous earth (Celatom MN-4; EP Minerals, LLC, Reno, NV) was placed in a 40 mm twin screw extruder. (Coperion Werner Pfleiderer ZSK-40mm MC, Stuttgart, Germany) was fed at a rate of 23 kg / hr. A water / sucrose solution made from 26.5% sucrose was injected at a flow rate of 70 mL / min after the crush zone of the extruder. The extruder was operated at 140 rpm with a 37 kW motor and a high torque shaft. The% torque range was 17-22. The resulting crushed yeast powder was cooled to 35 ° C. in the final water-cooled barrel. The wet extruded powder was assembled from a 1 mm hole diameter x 1 mm thick screen and fed into an LCI Multi-Granulator model number MG-55 (LCI Corporation, Charlotte, NC) set at 80 RPM. Extrudates were formed at a flow of 27 kg / hr, steady 2.2 amp current and dried using conventional drying equipment. Dry pellets approximately 1 mm in diameter x 6 to 10 mm long had a final moisture content of 1.7% as measured by a Sartorius MA35 moisture analyzer (Sartorius AG, Goettingen, Germany).

Extraction of Extruded Yeast Biomass Extruded yeast pellets were extracted using supercritical fluid phase carbon dioxide (CO ₂ ) as the extraction solvent to produce a triglyceride rich extract oil containing EPA. Specifically, yeast pellets were loaded into a 320 L stainless steel extraction vessel and filled between plugs of a polyester foam filtration mat (Aero-Flo Industries, Kingsbury, IN). The vessel is sealed and then CO ₂ is metered through a heat exchanger (preheater) with a commercial compressor (Pressure Products Industries) and fed into a vertical extraction vessel to feed triglyceride rich oil from the pellets of crushed yeast. Extracted. The extraction temperature was controlled by a preheater, and the extraction pressure was maintained by an automatic control valve (Kammer) located between the extraction vessel and the separator vessel. CO ₂ and oil extract were expanded to low pressure through this control valve. The extracted oil was recovered from the expansion solution as a precipitate in a separator. The temperature of the expanded CO ₂ phase in the fractionator was controlled by the use of an additional heat exchanger located upstream of the fractionator. This low pressure CO ₂ stream exited the top of the separator vessel and was recycled back to the compressor via a filter, condenser, and mass flow meter. Extracted oil was periodically withdrawn from the fractionator and recovered as product.

The extraction vessel was initially charged with 150 kg of extracted yeast pellets. The triglyceride rich oil was then extracted from the pellets with supercritical fluid CO _{2 at} 5000 psig (345 bar), 55 ° C., and a solvent feed ratio of 32 kg CO ₂ per kg starting yeast pellet. A total of 39.6 kg of extracted oil is recovered from the separator vessel and added to it with approximately 1000 ppm of two antioxidants, respectively: Covi-ox T70 (Cognis, Ontario, Canada) and Dadex RM (Neanders, Ontario, Canada) did. The extracted oil contained 661 mg ergosterol / 100 g oil as measured by GC analysis (below).

  Specifically, the ergosterol content was measured by high performance liquid chromatography (HPLC) with ultraviolet (UV) detection. An extracted oil sample (100 mg) was diluted with 14 mL of 9:10 2-propanol: 1-heptanol and mixed well. Calibration standards of 96% purity ergosterol (Alfa Aesar, Inc., Ward Hill, Mass.) Were prepared in the range of 10 to 300 μg / mL in 2-propanol. Samples and standards were run on an XDB-C8 HPLC column (4.6 mm id., 150 mm length, using an acetonitrile gradient of 0.02% ammonium carbonate-65% to 100% acetonitrile in water for 12.5 minutes. Chromatography on a particle size of 5 μm, Agilent Technologies, Inc., Wilmington, DE). The injection volume was 5 μL, the flow rate was 1.2 mL / min, and the column temperature was 50 ° C. The UV (282 nm) response of the ergosterol peak was compared to a calibration standard analyzed under the same conditions.

Distillation under SPD conditions The extracted oil was degassed and then passed through a 6 ″ stainless steel molecular still (POPE Scientific, Saukville, WI) using a feed rate of 12 kg / hr. Residual water was removed. The surface temperatures of the evaporator and condenser were set to 140 ° C. and 15 ° C., respectively. The vacuum was maintained at 15 torr. About 3% by weight of extracted oil was removed as water in the distillate. The dehydrated extracted oil was substantially free of phospholipids and contained 0.5 ppm phosphorus. At the time of visual inspection, the dehydrated extracted oil was turbid at room temperature.

  The dehydrated extracted oil was passed through the 6 ″ molecular still for a second time at a feed rate of 12 kg / hr. The vacuum was reduced to 1 mtorr and the evaporator and condenser surface temperatures were maintained at 240 ° C. and 50 ° C., respectively. About 7% by weight of dehydrated extracted oil was removed as a distillate; this fraction mainly contained free fatty acids and ergosterol. Triacylglycerol-containing fraction (ie, lipid-containing fraction or SPD refined oil) containing 284 mg ergosterol / 100 g oil (approximately 57% reduction in ergosterol content compared to the ergosterol content of the extracted oil) Also got. The SPD refined oil was clear after storage at 10 ° C. for several days.

Example 23
Preparation of SPD Refined Microbial Oil with Reduced Sterol Content from Untreated Yarrowia lipolytica Y9502 Biomass This example is via extrusion of dried untreated Yarrowia lipolytica Y9502 biomass. Crush, extract oil using supercritical fluid extraction [“SCFE”], and reduce the sterol content of the oil by distillation using short path distillation conditions to reduce the lipid-containing fraction (ie, SPD purified microorganisms) The means used to provide the oil) are described.

Preparation of dry untreated Yarrowia lipolytica Y9502 biomass The Y. lipolytica strain Y9502 was cultured in a two-stage fed-batch process and the resulting microbial biomass was according to the methodology described in Example 22A. Dehydrated, washed and dried.

Crushing via extrusion of dry untreated yeast biomass Dry untreated Y. lipolytica Y9502 biomass was fed to a twin screw extruder. Specifically, yeast biomass (containing about 37% total microbial oil) was transferred to a 70 mm twin screw extruder (Coperion Werner Pfleiderer ZSK-70 mm SCD, Stuttgart, Germany) with no diatomaceous earth at a rate of 270 kg / hr. I feed below.

  The extruder was operated at 150 rpm and 33 percent of the total amperage range with a 150 kW motor and high torque shaft. The resulting crushed yeast biomass was cooled to 81 ° C. in a final water-cooled barrel. The water content of the crushed biomass was 2.8% by weight as measured by a Sartorius MA35 moisture analyzer (Sartorius AG, Goettingen, Germany).

Extraction of Extruded Yeast Biomass Extruded yeast biomass is mixed with diatomaceous earth to prevent bed compaction and extracted using supercritical fluid phase CO ₂ as the extraction solvent and crude triglyceride oil containing EPA (ie, “extraction” Oil "). Specifically, a total of 82.7 kg of extruded yeast biomass is mixed with 41 kg of diatomaceous earth (Celatom MN-4; EP Minerals, LLC, Reno, NV) and configured in the same manner as described in Example 22B. Loaded into a 320 L stainless steel extraction vessel, except for the following: (i) the extraction temperature was controlled to 40 ° C. by a preheater; (ii) the extraction pressure was maintained at 4500 psig (310 bar); (iii) A solvent feed ratio of 44 kg CO ₂ / kg starting yeast was used for extraction. In this way, 23.2 kg of oil was extracted from the crushed yeast. The extracted oil contained 774 mg ergosterol / 100 g oil as determined by GC analysis according to the methodology of Example 22B.

Distillation under SPD conditions The extracted oil was passed through a 2 ″ glass molecular still to provide a dehydrated extracted oil. The flow rate was maintained at about 480 g / hr. The vacuum, evaporator and condenser temperatures were 0.2 mmHg, 130 ° C. and 60 ° C., respectively. The dehydrated extracted oil was then passed 3 times at different temperatures in a vacuum of 1 mtorr through a still as shown in the table below. After each pass, the ergosterol level, EPA content (as weight percent of TFA) and total omega-3 content (weight percent of TFA) of the triacylglycerol-containing fraction (ie lipid-containing fraction or SPD refined oil) As) was measured as described above.

  Thus, at 210 ° C., the ergosterol level of the SPD refined oil was 110 mg / 100 g oil, which was reduced to about 53 mg / 100 g oil at 240 ° C. Ergosterol was almost completely removed to 1 mg / 100 g oil when the temperature was further increased to 270 ° C. This is about 57%, about 86% and about 99.8% of the ergosterol content in the first pass, the second pass and the third pass, respectively, compared to the ergosterol content of the extracted oil. Respond to reduction.

  Regarding the PUFA content of the SPD refined oil, the data in Table 26 show that no significant degradation of EPA or total omega-3 content occurred even when the oil was passed through an SPD still at 270 ° C. Prove that.

  The third pass SPD refined oil was further analyzed for the appearance of unexpected components and contaminants using chromatographic profiling. Specifically, the tests have (i) gas chromatography with flame ionization detection (GC / FID); (ii) thin layer chromatography (TLC); and (iii) mass spectrometry, light scattering and ultraviolet detection. Performed by liquid chromatography (HPLC / MS / ELSD / UV). The GC / FID profile was run for the methyl ester of the SPD refined oil sample. TLC and HPLC / MS / ELSD / UV profiles were run directly for SPD refined oil. In all cases, the SPD refined oil profile was compared to a reference oil prepared using Y. lipolytica strain Y4305 biomass (material, supra).

  Specifically, the reference oil was generated from dry untreated Y. lipolytica Y4305 strain biomass according to the methodology described in Example 22A. The dried untreated biomass was mechanically crushed using a media mill with an oil to isohexane solvent ratio of 1-7. Residual biomass (ie cell debris) was removed using a decanter centrifuge and the solvent was evaporated to obtain an extracted oil containing triglycerides. The extracted oil was degummed using cold acetone with a ratio of extracted oil to solvent of 1 to 1.5 and then acid degummed with 50% aqueous citric acid. The degummed oil was then bleached with acid activated clay and deodorized at 210 ° C. for 30 minutes to obtain a reference oil sample.

  The chromatographic profile of the third pass SPD refined oil did not contain any peaks not found in the reference sample profile. Both samples were run on the same day under the same conditions. Furthermore, there were no unidentified peaks of the SPD refined oil with a significantly higher response than the corresponding peaks in the reference sample profile. Also, the third pass SPD refined oil peak has a higher response than the corresponding peak of the first pass or second pass SPD refined oil produced at low temperatures (ie, 210 ° C. and 240 ° C., respectively). Did not have. These analyzes show that removal of ergosterol at high temperatures using SPD does not result in the appearance of degradation products in the oil; therefore, application of this processing technique does not result in significant degradation of PUFA. Is assumed.

Example 24
Preparation of SPD Refined Microbial Oil with Reduced Sterol Content from Untreated Yarrowia lipolytica Y8672 Biomass This example uses dry unprocessed Yarrowia lipolytica Y8672 strain biomass, medium mill Crushing through the mechanical crushing used, extracting crude oil using isohexane solvent, reducing the sterol content of acetone degummed oil by distillation using short path distillation conditions, That is, the means used to provide the SPD refined microbial oil is described.

Preparation of dry untreated Yarrowia lipolytica strain Y8672 biomass Y. lipolytica strain Y8672 was cultured in a two-stage fed-batch process according to the methodology described in Example 22A and the resulting microbial biomass Was dehydrated, washed and dried.

Crushing and extraction via dry mill untreated yeast biomass and isohexane solvent to produce extract oil Dry untreated Y. lipolytica Y8672 strain biomass using isohexane solvent using medium mill It was crushed mechanically. Residual biomass (ie cell debris) was removed using a decanter centrifuge and the solvent was evaporated to obtain an extracted oil containing triglycerides.

  The extracted oil was analyzed using the methodology of Example 22B. As shown in the table below, the microbial oil contained 58.1 EPA% TFA.

  A portion of the extracted oil was degummed using low temperature acetone to a ratio of extracted oil to solvent of 1 to 1.5. The acetone degummed oil contained 880 mg ergosterol / oil 100 g and 74.5 ppm phosphorus.

Distillation under SPD conditions The acetone degummed oil was subjected to short path distillation according to the methodology of Example 22B (provided the evaporator temperature was set to 255 ° C). Distillate was hardly recovered during the first pass. This is because there was almost no water in the acetone degummed oil. During the second pass, about 12% by weight of distillate was recovered. The final ergosterol level of the triacylglycerol-containing fraction (ie lipid-containing fraction or SPD refined oil) is 106 mg / 100 g (approximately 88 ergosterol content compared to the ergosterol content of the acetone degummed oil). The SPD refined oil contained 66 ppm phosphorus.

Example 25
Preparation of Unconcentrated Microbial Oil Containing 56.1% EPA of Total Fatty Acid [“TFA”] This example is from microbial biomass of recombinant Yarrowia lipolytica Z1978 strain cells genetically engineered for EPA production. The isolation of the resulting unconcentrated microbial oil is described.

  Specifically, Y. lipolytica strain Z1978 was cultured using a two-step fed-batch process. The microbial oil is then isolated from the biomass via drying, extracted (via a combination of extrusion, pelletizing and supercritical fluid extraction), purified via short path distillation and uncontained containing 56.1 EPA% TFA. A concentrated triglyceride rich SPD refined oil (ie lipid containing fraction) was obtained.

Crushing and pelletizing via fermentation and extrusion of dried unprocessed Yarrowia lipolytica Z1978 strain biomass Fermentation of Y. lipolytica Z1978 strain culture as described in the previous material and fermentation of microbial biomass Was collected and dried. The dried untreated biomass was then fed into a twin screw extruder. Specifically, a mixture of biomass and 15% diatomaceous earth (Celatom MN-4 or Celite 209, EP Minerals, LLC, Reno, NV) was premixed and then ZSK-40mm MC twin screw extruder (Coperion Werner & Pfleiderer). , Stuttgart, Germany) at a rate of 45.5 kg / hr. A water / sucrose solution consisting of 26.5% sucrose was injected at a flow rate of 147 mL / min after the crush zone of the extruder. The extruder was operated in a% torque range of 20-23 at 280 rpm. The resulting crushed yeast powder was cooled to 35 ° C. in the final water-cooled barrel. The wet extruded powder was then assembled from a perforated dome die 1 mm diameter x 1 mm thick screen and fed into an LCI dome crusher model number TDG-80 (LCI Corporation, Charlotte, NC) set at 82 RPM. Extrudates were formed at 455-600 kg / hr (as the drying speed). The sample is run at a dry zone of 0.50 m ² with an air flow of 1150 standard cubic feet per minute [“scfm”] maintained at 100 ° C. and an air flow estimated at 500-600 scfm at 18 ° C. vibrating fluidized bed dryer having a cooling zone of ^{24m 2 (FBP-75, Carman} Industries, Inc., Jeffersonville, iN) was dried in. Dried pellets approximately 1 mm diameter x 6 to 10 mm long exit the dryer in the range of 25-30 ° C. and contain 5-6% final moisture as measured by O'Haus moisture analyzer (Parsippany, NJ) Had a rate.

Oil Extraction of Extruded Yeast Biomass Using the 320L stainless steel extraction vessel described in Example 22B, the extruded yeast pellets are extracted using supercritical fluid phase CO ₂ as the extraction solvent to extract unconcentrated triglyceride rich extract oil. Was generated.

The extraction vessel was initially charged with about 150 kg of extruded yeast pellets. Unconcentrated extracted oil was then extracted from the pellets with supercritical fluid CO _{2 at} 5000 psig (345 bar) at 55 ° C. and a solvent feed ratio in the range of 40-50 kg CO ₂ per kg starting yeast pellet. About 37.5 kg of unconcentrated extracted oil is recovered from the separator vessel, to which about 1000 ppm of each of the two antioxidants, namely Covi-ox T70 (Cognis, Mississauga, Canada) and Dadex RM (Neanders, Mississauga, Canada) was added.

Distillation under SPD conditions Unconcentrated extracted oil is degassed and then passed through a 6 ″ molecular still (POPE Scientific, Saukville, WI) using a feed rate of 12 kg / hr to remove residual water did. The surface temperatures of the evaporator and condenser were set to 140 ° C. and 15 ° C., respectively. The vacuum was maintained at 15 torr.

  The dehydrated extracted oil was passed through a molecular still for a second time at a feed rate of 12 kg / hr to remove unwanted low molecular weight compounds such as ergosterol and free fatty acids in the distillate. The vacuum was reduced to 1 mtorr and the evaporator surface temperature was maintained between 240 ° C and 270 ° C. A fraction containing triacylglycerol (ie, SPD refined oil) having a reduced sterol relative to the sterol content of the unconcentrated extracted oil was obtained. Unconcentrated SPD refined oil was cooled to below 40 ° C. before packaging.

Characterization of unconcentrated SPD refined oil from Yarrowia lipolytica Z1978 strain The fatty acid composition of unconcentrated SPD refined oil from Z1978 strain (ie, lipid-containing fraction) was determined after transesterification according to the methodology of Example 27. analyzed. The SPD refined oil contained 56.1 EPA% TFA as shown in Table 28 below, and DHA was undetectable (ie, <0.05%).

Example 26
Production of solid pellets from Nannochloropsis Algae and its oil extraction This example demonstrates the applicability of the methodology disclosed herein for use with microbial biomass other than Yarrowia Describe the tests performed to: Specifically, Nannochloropsis biomass was mixed with milling agent and binder to provide solid pellets. These pellets were subjected to supercritical CO ₂ extraction and the total extraction yield was compared.

  Kuehnle Agrosystems, Inc. (Honolulu, HI) offers a variety of purely cultured monoalgae stock algae for purchase. At the time of request, an algal KAS604 strain containing a Nannochloropsis species was proposed as a suitable microbial biomass with a lipid content of at least 20%. Biomass is grown under standard conditions (conditions that are not optimized for oil content), and Kuehnle Agrosystems, Inc. And then microalgae powder was purchased for use below.

  91.7 parts of microalgal powder was premixed in a bag with 8.3 parts of Celato MN-4 diatomaceous earth. The resulting dry mixture was fed to an 18 mm twin screw extruder (Coperion Werner Pfleiderer ZSK-18 mm MC) at 0.91 kg / hr. Along with the dry feed, a 31% aqueous solution of sugar made from 10.9 parts water and 5.0 parts sugar was injected at a flow rate of 2.5 mL / min after the crush zone of the extruder. The extruder provided a crushed yeast powder that was run at 200 rpm and a 46-81% torque range with a 10 kW motor and high torque shaft and cooled to 31 ° C. in the final water-cooled barrel.

  The fixable mixture was then assembled with a 1.2 mm hole diameter x 1.2 mm thick screen and fed into an MG-55 LCI dome grinder set at 20 RPM. Extrudates were formed at 20 kg / hr and 6-7 amp current. The sample was dried in a Sherwood dryer at 70 ° C. for 20 minutes to provide a solid pellet with a final moisture level of 4.9%. Solid pellets approximately 1.2 mm diameter x 2-8 mm long were 82.1% algae and the remainder of the composition was pelleting aid. The amount of total and free oil in the solid Nannochloropsis pellets was then measured and compared to the amount of oil extracted from the solid Nannochloropsis pellets by SCF.

Measurement of the total oil content of solid Nannochloropsis pellets Specifically, for the pelleted sample, the total oil is gently ground into a fine powder using a mortar or pestle and then for analysis Aliquots (in triplicate) were weighed. Fatty acids (predominantly present as triglycerides) in the samples were converted to the corresponding methyl esters by reaction with acetyl chloride / methanol at 80 ° C. A C15: 0 internal standard was then added to each sample in known amounts for calibration purposes. Individual fatty acids were measured by capillary gas chromatography using flame ionization detection (GC / FID). The sum of fatty acids (expressed in triglyceride form) was 6.1%; this was interpreted as the total oil content of the sample. After normalization, the algae in the pellet represented only 82.1% of the total mass, so the total oil content of the algae was determined to be 7.4% (ie, 6.1% divided by 0.821). .

  The distribution of individual fatty acids within the total oil sample is shown in the table below.

Measurement of free oil content of solid Nannochloropsis pellets Free oil is usually measured by stirring the sample with n-heptane, centrifuging and then evaporating the supernatant to dryness. The resulting residual oil is then weighed and expressed as a weight percentage of the original sample. This procedure was found to be inadequate for pelleted algae samples. This is because the resulting residue contained a significant level of dye. Therefore, the above procedure was modified by collecting the above residue, adding a known amount of C15: 0 internal standard, and then analyzing by GC / FID using the same parameters as the total oil measurement. In this way, the free oil content of the sample was measured as 3.7%. After normalization, the free oil content of the algae was measured to be 4.5% (ie 3.7% divided by 0.821).

SCF extraction of solid Nannochloropsis pellets An extraction vessel was loaded with 24.60 g solid pellets (dry weight basis) and corrected for milling agent and binder yielded approximately 21.24 g of algae. The pellet was flushed with CO ₂ and then heated to about 40 ° C. and pressurized to about 311 bar. The pellets were extracted for about 6.7 hr at a CO ₂ flow rate of 3.8 g / min under these conditions, resulting in a final solvent feed (S / F) ratio of about 71 g CO ₂ / g algae. Extraction yield is 6.2% of loaded algae
Met.

  Based on the above, the method described herein [i.e. (a) crushing containing crushed microbial biomass by mixing a microbial biomass having a certain moisture level and containing oil-bearing microorganisms and at least one oil-absorbing crushing agent. Providing a biomass mixture; (b) providing at least one binder with the crushed biomass mixture to provide a fixable mixture capable of forming solid pellets; and (c) the solid from the fixable mixture. It is concluded that the method comprising the step of forming pellets can be successfully utilized to produce solid pellets containing crushed microbial biomass from Nannochloropsis. Although this methodology is hypothesized to prove suitable for many other oleaginous microorganisms, it is expected that process optimization for each particular microorganism will result in increased crushing efficiency.

  In addition, this example demonstrates that solid Nannochloropsis pellets can be extracted with solvents in various ways to provide an extract containing oil. As is well known in the art, different extraction methods result in different amounts of extracted oil; it is expected that the extraction yield can be increased for a particular solid pellet during optimization of the extraction process. Further, it is anticipated that the extracted oil can be subjected to distillation under short path distillation conditions in accordance with the disclosure herein.

Example 27
Preparation of Microbial Oil Containing 58.2% EPA of Total Fatty Acid [“TFA”] This example was obtained from microbial biomass of recombinant Yarrowia lipolytica cells genetically engineered for EPA production The isolation of microbial oil is described. The microbial oils are then enriched by various means as described below in Examples 28-30.

  The microbial oil was isolated from Y. lipolytica strain Y8672 biomass via an isohexane solvent and purified to obtain an unconcentrated triglyceride rich refined oil containing 58.2 EPA% TFA.

Fermentation of Y. lipolytica strain Y8672 biomass and extraction of microbial oil therefrom According to the material, Y. lipolytica strain Y8672 was grown in a two-stage fed-batch process, dehydrated and washed. It was then drum dried to reduce moisture to less than 5% to ensure oil stability during short term storage and transport of untreated microbial biomass.

  The microbial biomass was then subjected to mechanical disruption using an isohexane solvent to extract EPA rich microbial oil from the biomass. Residual biomass (ie, cell debris) was removed and the solvent was evaporated to obtain an extracted oil. The extracted oil was degummed using phosphoric acid and refined with a 20 Baume caustic to remove phospholipids, trace metals and free fatty acids. Bleaching with silica and clay was used to adsorb colored compounds and small amounts of oxidation products. The final deodorization process stripped of volatile, malodor and additional colored compounds to obtain unconcentrated refined microbial oils containing PUFA in their neutral triglyceride form.

Characterization of the microbial oil from Y. lipolytica strain Y8672 The fatty acid composition of the unconcentrated refined oil was analyzed using the GC method described in Example 22A.

  The results obtained from GC analysis for unconcentrated Y8672 refined oil are shown in Table 30 below. The refined oil contained 58.2 EPA% TFA and no DHA was detectable (ie <0.05%).

  Those skilled in the art expect that microbial oils of similar composition can be obtained from Y. lipolytica strain Y8672 when the biomass is subjected to pelletization, extraction, and then distillation under short path distillation conditions. .

Example 28
Enrichment of microbial oils via urea adduct formation This example shows EPA concentrates containing up to 78% EPA ethyl ester, substantially free of DHA, measured as weight percent of oil, via urea adduct formation. It is demonstrated that it can be obtained upon enrichment of the unconcentrated refined oil from Example 27.

  First KOH (20 g) was dissolved in 320 g absolute ethanol. The solution was then mixed with 1 kg of unconcentrated refined oil from Example 27 and heated to about 60 ° C. for 4 hours. The reaction mixture was calmed overnight in a separatory funnel for complete phase separation. After removing the lower glycerol fraction, a small amount of silica was added to the upper ethyl ester fraction to remove excess soap. Ethanol was removed on a rotary evaporator under vacuum at about 90 ° C. to give a clear but light brown ethyl ester.

  The ethyl ester (20 g) was mixed with 40 g urea and 100 g ethanol (90% aqueous) at about 65 ° C. The mixture was maintained at this temperature until it turned into a clear liquid. The mixture was then cooled for urea crystal and adduct formation and held at room temperature for about 20 hours. The solid was then removed via filtration and the liquid fraction was run on a rotary evaporator to remove the ethanol. The collected ethyl ester fraction was washed with a first washing solution of 200 mL of warm water and then with a second washing solution. The pH of the solution was first adjusted to 3-4 before the aqueous fraction was decanted off. The ethyl ester fraction was then dried to remove residual water.

  To determine the fatty acid ethyl ester [“FAEE”] concentration of the ethyl ester fraction, use the same GC conditions and calculations as described above in Example 22A after dilution of FAEE in toluene / hexane (2: 3). And analyzed directly to determine the FAME concentration. The only modifications in the methodology were: i) C23: 0EE was used as an internal standard instead of C15: 0; no molecular weight conversion factor of 1.042 to 1.052 was required.

  However, EPA ethyl ester [“EPA-EE”] was subjected to a slightly modified procedure from that described above. Specifically, a reference EPA-EE standard of known concentration and purity was prepared to contain approximately the same amount of EPA-EE and the same amount of C23: 0EE internal standard expected in the analytical sample. The exact amount (mg) of EPA-EE in the sample is given by the formula: (EPA-EE peak area / C23: 0 EE peak area) x (C23: 0 EE peak area in the calibration standard / EPA-EE in the calibration standard). Calculate according to the area of the peak x (mgEPA-EE in the calibration standard). All internal and reference standards were obtained from Nu-Chek Prep, Inc.

  Thus, the FAEE concentration was determined in the enriched oil fraction, ie the EPA concentrate. Specifically, as shown in Table 31, enrichment of unconcentrated refined oil through urea adduct formation has 77% EPA ethyl ester measured as weight percent of oil and is substantially free of DHA. An EPA concentrate was obtained.

  Those skilled in the art will readily convert EPA concentrates containing 77% EPA ethyl ester, substantially free of DHA, measured as weight percent of oil, using means well known to those skilled in the art. Recognize that a form of EPA concentrate can be obtained (ie, EPA ethyl esters can be converted to free fatty acids, triacylglycerols, methyl esters, and combinations thereof). Thus, for example, 77% of EPA ethyl ester is re-esterified to triglycerides via glycerolysis and is measured in weight percent of oil to contain at least 70% by weight of EPA, in the form of a triglyceride substantially free of DHA. An EPA concentrate can be provided.

Example 29
Enrichment of Microbial Oil via Liquid Chromatography This example shows EPA concentrates containing up to 95.4% EPA ethyl ester and substantially free of DHA, measured as weight percent of oil, It is demonstrated that the method can be obtained upon enrichment of unconcentrated refined oil from Example 27.

  The unconcentrated refined oil from Example 27 was transesterified to the ethyl ester using a method similar to that described in Example 28, but with some modification (ie, to potassium hydroxide as a base catalyst). Use sodium ethoxide instead).

  The ethyl esters were then enriched using Equaleq (Isle of Lewis, Scotland) using their liquid chromatographic purification techniques. Various enrichments were achieved (see, eg, experimental data for Sample # 1 and Sample # 2 below). Thus, as shown in Table 32, enrichment of unconcentrated refined oil via liquid chromatography has up to 95.4% EPA ethyl ester, measured as weight percent of oil, and is substantially free of DHA. An EPA concentrate was obtained.

  Those skilled in the art will know to those skilled in the art EPA concentrates that contain either 82.8% EPA ethyl ester or 95.4% EPA ethyl ester, substantially free of DHA, measured as weight percent of oil. Recognizing that EPA ethyl esters can be easily converted using well-known means to obtain alternative forms of EPA concentrates (ie, EPA ethyl esters are converted to free fatty acids, triacylglycerols, methyl esters, and combinations thereof) Can be converted). Thus, for example, 82.8% EPA ethyl ester or 95.4% EPA ethyl ester is re-esterified to triglycerides via glycerolysis and contains at least 70% by weight EPA, measured as weight percent oil, EPA concentrates in the form of triglycerides substantially free of DHA can be produced.

Example 30
Enrichment of Microbial Oil via Supercritical Fluid Chromatography This example shows an EPA concentrate containing up to 89.8% EPA ethyl ester, substantially free of DHA, measured as weight percent oil. It is demonstrated that it can be obtained upon enrichment of the unconcentrated refined oil from Example 27 using the critical fluid chromatography [“SFC”] method.

Unconcentrated refined oil from Example 27, transesterified ethyl ester using sodium ethoxide as the base catalyst, followed by removal of the compounds which are insoluble in supercritical CO ₂ was treated through the adsorption column did. The treated ethyl ester oil is then D. Purified by Pharma (Bexbach, Germany) using their supercritical chromatography techniques. Various enrichments were achieved (see, eg, experimental data for Sample # 1 and Sample # 2 below). Thus, as shown in Table 33, enrichment of unconcentrated refined oil via SFC has 85% and 89.8% EPA ethyl ester measured as weight percent of oil and is substantially free of DHA. An EPA concentrate was obtained.

  Those skilled in the art will know EPA concentrates that contain either 85% EPA ethyl ester or 89.8% EPA ethyl ester, substantially free of DHA, measured as weight percent of the oil. Recognize that means can be easily converted to obtain alternative forms of EPA concentrate (ie, convert EPA ethyl esters to free fatty acids, triacylglycerols, methyl esters, and combinations thereof) be able to). Thus, for example, 85% EPA ethyl ester or 89.8% EPA ethyl ester is re-esterified to triglycerides via glycerolysis and contains at least 70% by weight EPA, measured as weight% oil, substantially Can result in an EPA concentrate in triglyceride form free of DHA.

Example 31
Preparation of Microbial Oil Containing 56.1% EPA of Total Fatty Acid [“TFA”] This example was obtained from microbial biomass of recombinant Yarrowia lipolytica cells genetically engineered for EPA production The isolation of microbial oil is described. The microbial oil was then enriched by fractional distillation as described in Example 32 below.

  Specifically, the Y. lipolytica Z1978 strain was engineered with a recombinant gene to allow the production of about 58.7 EPA% TFA and cultured using a two-step fed-batch process. The microbial oil is then isolated from the biomass via drying, extracted (via a combination of extrusion, pelletizing and supercritical fluid extraction), purified via short path distillation and uncontained containing 56.1 EPA% TFA. A concentrated triglyceride rich SPD refined oil (ie lipid containing fraction) was obtained.

Crushing and Pelletization via Fermentation and Extrusion of Dried Untreated Y. lipolytica Z1978 Strain Biomass Ferment a Y. lipolytica Z1978 strain culture as described in the Materials section above, The microbial biomass was collected and dried.

The dried untreated biomass was then fed into a twin screw extruder. Specifically, a mixture of biomass and 15% diatomaceous earth (Celatom MN-4 or Celite 209, EP Minerals, LLC, Reno, NV) was premixed and then ZSK-40mm MC twin screw extruder (Coperion Werner & Pfleiderer). , Stuttgart, Germany) at a rate of 45.5 kg / hr. A water / sucrose solution consisting of 26.5% sucrose was injected at a flow rate of 147 mL / min after the crush zone of the extruder. The extruder was operated in a% torque range of 20-23 at 280 rpm. The resulting crushed yeast powder was cooled to 35 ° C. in the final water-cooled barrel. The wet extruded powder was then assembled from a perforated dome die 1 mm diameter x 1 mm thick screen and fed into an LCI dome crusher model number TDG-80 (LCI Corporation, Charlotte, NC) set at 82 RPM. Extrudates were formed at 455-600 kg / hr (as the drying speed). The sample is run at a dry zone of 0.50 m ² with an air flow of 1150 standard cubic feet per minute [“scfm”] maintained at 100 ° C. and an air flow estimated at 500-600 scfm at 18 ° C. vibrating fluidized bed dryer having a cooling zone of ^{24m 2 (FBP-75, Carman} Industries, Inc., Jeffersonville, iN) was dried in. Dried pellets approximately 1 mm diameter x 6 to 10 mm long exit the dryer in the range of 25-30 ° C. and contain 5-6% final moisture as measured by O'Haus moisture analyzer (Parsippany, NJ) Had a rate.

Oil Extraction of Extruded Yeast Biomass Using the 320L stainless steel extraction vessel and configuration described in Example 22B, the extruded yeast pellets are extracted using supercritical fluid phase CO ₂ as the extraction solvent to extract unconcentrated extracted oil. Was generated. The oil extract was periodically withdrawn from the fractionator and recovered as product.

The extraction vessel was initially charged with about 150 kg of extruded yeast pellets. Unconcentrated extracted oil was then extracted from the pellets with supercritical fluid CO _{2 at} 5000 psig (345 bar) at 55 ° C. and a solvent feed ratio in the range of 40-50 kg CO ₂ per kg starting yeast pellet. About 37.5 kg of unconcentrated extracted oil is recovered from the separator vessel, to which about 1000 ppm of each of the two antioxidants, namely Covi-ox T70 (Cognis, Mississauga, Canada) and Dadex RM (Neanders, Mississauga, Canada) was added.

Distillation under SPD conditions Unconcentrated extracted oil is degassed and then passed through a 6 ″ molecular still (POPE Scientific, Saukville, WI) using a feed rate of 12 kg / hr to remove residual water did. The surface temperatures of the evaporator and condenser were set to 140 ° C. and 15 ° C., respectively. The vacuum was maintained at 15 torr.

  The dehydrated extracted oil was passed through a molecular still for a second time at a feed rate of 12 kg / hr to remove unwanted low molecular weight compounds such as ergosterol and free fatty acids in the distillate. The vacuum was reduced to 1 mtorr and the evaporator surface temperature was maintained between 240 ° C and 270 ° C. A triacylglycerol-containing fraction (ie lipid-containing fraction or SPD refined oil) having a reduced sterol relative to the sterol content of the unconcentrated extracted oil was obtained. Unconcentrated SPD refined oil was cooled to below 40 ° C. before packaging.

Characterization of SPD refined oil from Yarrowia lipolytica strain Z1978 The fatty acid composition of unconcentrated SPD refined oil from strain Z1978 was analyzed after transesterification according to the methodology of Example 27. The SPD refined oil contained 56.1 EPA% TFA as shown in Table 34 below, and DHA was undetectable (ie, <0.05%).

Example 32
Enrichment of Microbial Oil via Fractionation This example uses a fractionation method for EPA concentrates containing up to 74% EPA ethyl ester and substantially free of DHA, measured as weight percent of oil. It is demonstrated that it can be obtained upon enrichment of the unconcentrated SPD refined oil from Example 31.

  25 kg of unconcentrated microbial oil from Example 31 was added to a 50 L glass flask. 7.9 kg of absolute ethanol and 580 g of sodium ethoxide (21% in ethanol) were then added to the flask. The mixture was heated to reflux at about 85 ° C. for at least 30 minutes. The reaction was monitored by thin layer chromatography and a diluted sample of oil was spotted on a silica plate and separated using an acetic acid / hexane / ethyl ether solvent mixture. Spots consisting of unreacted TAG were detected by iodine staining. Spots that were absent or almost undetectable were considered to indicate completion of the reaction. After reaching the end of reaction, the mixture was cooled to below 50 ° C. and the phases were separated. The glycerol-containing lower layer was separated and discarded. The organic upper layer was washed with 2.5 L of 5% citric acid, and the recovered organic layer was then washed with 5 L of 15% aqueous sodium sulfate. The aqueous phase was discarded again and the ethyl ether phase was distilled with ethanol at about 60 ° C. in a rotary evaporator to remove residual water. Approximately 25 kg of oil in ethyl ester form was recovered.

  The ethyl ester was then fed to a 4 ″ hybrid wiped film and fractionation system (POPE Scientific, Saukville, Wis.) At a feed rate of 5 kg / hr to enrich the EPA ethyl ester. The evaporator temperature was set to about 275 ° C. under a vacuum of 0.47 torr. The head temperature of the packed column was about 146 ° C. Low molecular weight ethyl ester, mainly C18, was removed from the overhead as a light fraction. The extracted EPA ethyl ester was collected as a heavy fraction and subjected to a second distillation primarily to remove color and polymer. The second distillation was carried out in a 6 "molecular still (POPE Scientific, Saukville, WI) at a feed rate of 20 kg / hr. The evaporator was operated at about 205 ° C and the internal condenser temperature setting was about 10 ° C and a vacuum of 0.01 torr. About 7-10% by weight of the ethyl ester was removed to give a clear light EPA concentrate. The final EPA concentrate contained 74% EPA ethyl ester, measured as weight percent of oil, and was substantially free of DHA.

  Those skilled in the art will readily convert EPA concentrates containing 74% EPA ethyl ester, substantially free of DHA, measured as weight percent of the oil, using means well known to those skilled in the art. Recognize that a form of EPA concentrate can be obtained (ie, EPA ethyl esters can be converted to free fatty acids, triacylglycerols, methyl esters, and combinations thereof). Thus, for example, 74% EPA ethyl ester is re-esterified to triglycerides via glycerolysis and contains at least 70% by weight of EPA, measured as weight% of oil, and is substantially in the form of triglyceride free of DHA. A concentrate can be provided.

Example 33
EPA concentrate is substantially free of environmental pollutants This example contains at least 70% by weight of EPA, measured as weight percent of oil, substantially free of DHA, and the weight of TFA Both microbial oils, measured as%, containing 30-70% by weight EPA and substantially free of DHA, demonstrate that they are substantially free of environmental pollutants.

  An equivalent sample of unconcentrated refined oil from the Yarrowia lipolytica strain Y8672 was prepared as described in Example 27. Mg / g World Health Organization of polychlorinated biphenyls [“PCB”], (CAS number 1336-36-3), polychlorinated dibenzodioxins [“PCDD”] and polychlorinated dibenzofurans [“PCDF”] in unconcentrated extracted oil The concentration, measured as the World Health Organization International Equivalent [“WHO TEQ”], was measured according to EPA Method 1668 Rev A. Extremely low or undetectable levels of environmental contaminants were detected.

  Based on the above results, the concentrations of PCB, PCDD, and PCDF in the unconcentrated extracted oil of Example 27 and the unconcentrated SPD refined oil of Example 31 were also extremely low or undetectable in the present specification. Of environmental pollutants. Similarly, EPA ethyl ester concentrations in Examples 28, 29, 30 and 32, enriched through urea adduct formation, liquid chromatography, SFC and fractional distillation, respectively, are also extremely low or detected herein. It is assumed that it should contain impossible levels of environmental pollutants. This is because they are produced from unconcentrated oils that are substantially free of environmental pollutants themselves.

  More specifically, Table 35 lists the expected TEQ levels for PCB, PCDD, and PCDF in the EPA concentrates in Examples 28, 29, 30 and 32. For comparison, the concentration of the same compound in fish oil stripped with contaminants as described in US Pat. No. 7,732,488 is also included. It is noted that US Pat. No. 7,732,488 provides a special treatment that reduces those environmental pollutants to an acceptable level.

  As noted above, the EPA ethyl ester concentrates in Examples 28, 29, 30 and 32 have lower levels of PCB, PCDD, and the pollutant stripped fish oil in US Pat. No. 7,732,488. Has PCDF. In fact, the contaminant level of PCDF is expected to be below the detection limit of the analytical method used.

Example 34
Enrichment of Microbial Oil via Fractionation and Liquid Chromatography This example includes EPA containing up to 97.4% EPA ethyl ester, measured as weight percent of oil, and substantially free of DHA, NDPA and HPA It is demonstrated that a concentrate can be obtained upon enrichment of unconcentrated refined oil using a combination of fractional distillation and liquid chromatography methods.

Lipid-containing fractions were obtained from Yarrowia lipolytica strain Y9502 (supra, Example 31; see also US Patent Publication No. 2010-0317072-A1). Specifically, the strain was cultured as described in Example 31, recovered, crushed via extrusion and pelletization, and extracted using supercritical fluid phase CO ₂ . The unconcentrated extracted oil was then purified under SPD conditions (Example 31).

Characterization of SPD refined oil from Yarrowia lipolytica Y9502 strain The fatty acid composition of unconcentrated SPD refined oil from Y9502 strain was analyzed according to the methodology of Example 27. As shown in Table 36 below, the SPD refined oil contained 54.7 EPA% TFA and DHA, NDPA and HPA were undetectable (ie, <0.05%).

Enrichment of SPD refined oil from Yarrowia lipolytica strain Y9502 The SPD refined oil was transesterified to the ethyl ester using a method similar to that described in Example 29 and described in Example 31. It was further subjected to fractional distillation. The fractionated EPA concentrate contained 71.9% EPA ethyl ester, measured as weight percent of oil, and was substantially free of DHA, NDPA and HPA (the title “Minute” in Table 37 below). (See “Tome”).

  The fractionated ethyl esters were then enriched using Equaeq (Isle of Lewis, Scotland) using their liquid chromatographic purification techniques. Enrichment of fractionated EPA concentrate via liquid chromatography results in a final having up to 97.4% EPA ethyl ester, measured as weight percent of oil, and substantially free of DHA, NDPA and HPA An EPA concentrate was obtained (see the heading “Liquid Chromatography Enrichment” in Table 37 below).

One skilled in the art can easily obtain an EPA concentrate containing 97.4% EPA ethyl ester, measured as weight percent of oil, and substantially free of DHA, NPDA and HPA using means well known to those skilled in the art. It is recognized that EPA ethyl esters can be converted to free fatty acids, triacylglycerols, methyl esters, and combinations thereof. Thus, for example, 97.4% of EPA ethyl ester is re-esterified to triglycerides via glycerolysis and contains at least 70% by weight of EPA, measured as weight% of oil, substantially comprising DHA, NPDA and HPA EPA concentrate in triglyceride form free of
Furthermore, EPA concentrates prepared by the methods of the invention herein from any microbial biomass of recombinant Yarrowia cells that have been genetically engineered for EPA production substantially contain DHA, NDPA, and HPA. It is noted that it is not expected. The results obtained above based on the microbial oil obtained from Y. lipolytica strain Y9502 in which the final EPA concentrate is substantially free of DHA, NDPA and HPA are shown in Example 27 and Example 31. Expected from EPA concentrates prepared from microbial oils obtained from Early microorganisms containing 30-70 wt% EPA measured as wt% TFA, obtained from Yarrowia where DHA, NDPA and HPA impurities accumulate in excess of 25% of dry cell weight as oil Since it is not present in the oil, fatty acid impurities are not present in the EPA concentrate produced therefrom.

The present invention is summarized as follows.
1. (A) pelletizing microbial biomass having a moisture level and containing oil-bearing microorganisms;
(B) a step of extracting the pelleted microbial biomass of step (a) to produce an extracted oil; and (c) a step of distilling the extracted oil of step (b) at least once under short path distillation conditions. Wherein the distillation produces a distillate fraction and a lipid-containing fraction.
2. The method according to 1 above, wherein the oil-containing microorganism is selected from the group consisting of yeast, algae, fungi, bacteria, Euglena, stramenopile and oomycete.
3. The method according to 1 above, wherein the oil-containing microorganism contains at least one polyunsaturated fatty acid in oil.
4). The method of claim 1, wherein the moisture level of the microbial biomass is in the range of about 1 to 10 weight percent.
5. The step (a) of pelletizing the microbial biomass comprises:
(1) Providing a crushed biomass mixture containing crushed microbial biomass by mixing the microbial biomass and at least one pulverizing agent capable of absorbing oil;
(2) blending the crushed biomass mixture with at least one binder to provide a fixable mixture capable of forming solid pellets; and (3) forming the fixable mixture into solid pellets; The method of claim 1, comprising providing pelleted microbial biomass.
6). The crushed microbial biomass,
(A) a total specific energy input (SEI) of about 0.04 to 0.4 KW / (kg / hr);
(B) a compaction zone using bush elements with progressively shorter pitch lengths; and (c) produced in a twin screw extruder including a compression zone using flow restriction; 6. The method according to 5, wherein the method precedes the compression band.
7). (A) the at least one grinding agent is
(I) the at least one grinding agent is a particle having a Moh hardness of 2.0 to 6.0 and an oil absorption coefficient of 0.8 or greater measured according to ASTM method D1483-60;
(Ii) the at least one milling agent is selected from the group consisting of silica and silicate; and (iii) the at least one milling agent comprises microbial biomass, milling agent and binder in the solid pellet. Present from about 1 to 20 percent by weight relative to the sum of the masses;
And / or (b) said at least one binder has the property selected from the group consisting of:
(Iv) the at least one binder is selected from water and carbohydrates selected from the group consisting of sucrose, lactose, fructose, glucose, and soluble starch; and (v) the at least one binder is Present from about 0.5 to 10 percent by weight relative to the sum of the masses of microbial biomass, grinder and binder in the solid pellet;
Having a characteristic selected from the group consisting of:
6. The method according to 5 above.
8). (A) the step (1) of mixing the microbial biomass and the step (2) of blending at least one binder are performed in an extruder, performed simultaneously, or performed simultaneously in an extruder;
(B) forming the solid pellet from the fixable mixture (3) comprises:
(I) extruding the fixable mixture through a die to form a strand;
A combination of (ii) drying and breaking the strand; and (iii) extruding the fixable mixture through a die to form a strand and drying and breaking the strand (ii) Comprising a step selected from the group consisting of:
6. The method according to 5 above.
9. The solid pellet is
(A) the solid pellet has an average diameter of about 0.5 to about 1.5 mm and an average length of about 2.0 to about 8.0 mm;
(B) the solid pellet has a moisture level of about 0.1 to 5.0 weight percent; and (c) the solid pellet is the sum of the masses of microbial biomass, grinding agent and binder in the solid pellet. Microbial biomass comprising about 70 to about 98.5 weight percent of oleophilic microorganisms, about 1 to about 20 weight percent of at least one oil-absorbable grinder and about 0.5 to 10 weight percent of at least one bond 6. The method according to 5 above, having a property selected from the group consisting of comprising an agent.
10. In step (b), the extraction is performed with an organic solvent to produce an extracted oil, and the extracted oil is degummed and optionally bleached prior to the step (c) of distilling the extracted oil. The method according to 1 above.
11. In step (b), the extraction is:
(1) treating the pelletized microbial biomass with a solvent containing liquid or supercritical fluid carbon dioxide, the pelleted microbial biomass containing oil-containing microorganisms,
(I) an extract comprising a lipid fraction substantially free of phospholipids; and (ii) residual biomass comprising phospholipids;
Further comprising in the oil at least one polyunsaturated fatty acid to obtain: and (2) at least one polyunsaturated by fractionating the extract obtained in step (1) section (i) at least once Obtaining an extracted oil having a refined lipid composition comprising fatty acids, wherein the refined lipid composition is enriched with triacylglycerol to the oil composition of pelleted microbial biomass that has not been treated with a solvent. 2. The method according to 1 above, comprising:
12 (I) the extracted oil of step (b) contains a sterol fraction;
(Ii) the distillate fraction of step (c) comprises the sterol;
(Iii) the lipid-containing fraction of step (c) comprises a reduced amount of the sterol compared to the amount of sterol in the extracted oil that has not been subjected to short path distillation;
2. The method according to 1 above.
13. 13. The method of claim 12, wherein the sterol fraction comprises one or more sterols selected from the group consisting of stigmasterol, ergosterol, brassicasterol, campesterol, β-sitosterol and desmosterol.
14 At least 300 mg of said extracted oil having a refined lipid composition enriched with triacylglycerols against an oil composition of pelleted microbial biomass comprising at least one polyunsaturated fatty acid and not treated with a solvent 12. The method of claim 11, further comprising a / 100 g sterol fraction.
15. The extracted oil having a refined lipid composition was distilled at least once under short-path distillation conditions, and the distillation was not subjected to a distillate fraction containing sterols and triacylglycerol and short-path distillation 15. The method of claim 14, wherein a lipid-containing fraction is produced comprising a reduced amount of sterol compared to the amount of sterol in the extracted oil having a lipid composition.
16. 3. The method according to 2 above, wherein the yeast is Yarrowia.
17. The Yarrowia is linoleic acid, γ-linolenic acid, eicosadienoic acid, dihomo-γ-linolenic acid, arachidonic acid, docosatetraenoic acid, ω-6 docosapentaenoic acid, α-linolenic acid, stearidonic acid, eico 16 wherein the recombinant gene has been engineered for the production of polyunsaturated fatty acids selected from the group consisting of satrienoic acid, eicosatetraenoic acid, eicosapentaenoic acid, ω-3 docosapentaenoic acid and docosahexaenoic acid The method described.
18. (D) further comprising transesterifying the lipid-containing fraction of step (c); and (e) enriching the transesterified lipid-containing fraction of step (d) to obtain an oil concentrate. The method according to 1.
19. (I) the oil-bearing microorganisms accumulate as microbial oil in excess of 25% of their dry cell mass;
(Ii) the microbial oil comprises 30 to 70 weight percent eicosapentaenoic acid, measured as a weight percent of total fatty acids, and substantially free of docosahexaenoic acid;
(Iii) the enrichment of step (e) is by a combination of at least two processes, said first process comprising fractional distillation, said second process comprising urea adduct formation, liquid chromatography, Selected from the group consisting of supercritical fluid chromatography, simulated moving bed chromatography, real moving bed chromatography and combinations thereof;
(Iv) the oil concentrate is an eicosapentaenoic acid concentrate comprising at least 70 weight percent eicosapentaenoic acid, measured as mass percent of oil, and substantially free of docosahexaenoic acid;
19. The method according to 18 above.
20. 12. The method according to 11 above, wherein the residual biomass containing phospholipid is further extracted to isolate the phospholipid.

Claims (1)

(A) a step of pelletizing microbial biomass having a moisture level and containing oil-bearing microorganisms :
(1) mixing the microbial biomass and at least one pulverizing agent capable of absorbing oil to provide a crushed biomass mixture;
(2) blending the crushed biomass mixture with at least one binder to provide a fixable mixture capable of forming solid pellets; and
(3) forming the fixable mixture into solid pellets to provide pelleted microbial biomass
Comprising the steps of :
(B) a step of extracting the pelleted microbial biomass of step (a) to produce an extracted oil; and (c) a step of distilling the extracted oil of step (b) at least once under short path distillation conditions. Wherein the distillation produces a distillate fraction and a lipid-containing fraction.

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